Page 1
Engine Operation &
Maintenance
Engine Model:
SFGLD360/480 Gas
Generator Set Models:
750/1000REZK
See Inside Front Cover for Service Assistance Information
TP-6991 8/18b
Page 2
Service Assistance
W ARNING: This product can expose you
to chemicals, including carbon monoxide
and benzene, which are known to the State
of California to cause cancer and birth
defects or other reproductive harm.
For more information go to
www.P65warnings.ca.gov
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
D Visit the Kohler Co. website at KOHLERPower.com.
D Lookatthe labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product.
D Call toll free in the US and Canada 1-800-544-2444.
D Outsidethe US and Canada, call the nearest regional
office.
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler EMEA Headquarters
Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: (31) 168 331630
Fax: (31) 168 331631
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Page 3
Page 4
Page 5
DearCustomers,
Pleasebeadvised thatEPAregulation 40 CFR part 60 subpart JJJJ placescertainrequirementson
owners and operators of new stationary spark ignition internal combustion en gines.You have
purchasedaEPApre‐certifiedGuascorgasengineper40CFRpart 60 subpart JJJJ and, therefore,
should adhere to the compliance requirements fo
r pre‐certified enginesYour engine has been
certified for stationary emergency use only.As such, there is no time limit for use of this
emergencystationaryICEengineinemergencysituations‐asdeterminedbyanauthorizedentity.
However,theEPA does strictly regulate how much,and when this unit can be operated fornon‐
emerge
ncysituations.Pleaseconsulttheregulationsforspecifics.
This pre‐certification does not exempt you from State or local air authority regulations.In fact,
manyStateandlocalairauthoritieshaveadoptedregulationsmorestringentthantheEPAandwill
require on‐site testing to their specif
ic test protocols regardless of this pre‐certification.We
adviseyou to consultallapplicableregulationsin determiningyourcomplianceobligations and to
checkwith your localauthorityto make sure yourinstallationis incompliancewithlocal lawsand
regulations.
GuascorengineswillsatisfytheaforementionedEPAregulationsonlyiftheengineconfigurationis
not changed, the en
gine is commissioned by a factory technician, approved Dealer or Service
Company technician, the engine maintenance schedule is followed, and the supply gas to the
enginesmeets the following fuel specification IC‐G‐D‐30‐021. The Dresser‐Rand business, part of
SiemensPowerandGasDivision,disclaimsliabilityforal
loperationalfactorsoutsideofitscontrol,
whichmayaffectyourenginesemissionsoutput.
Please contact Dresser‐Rand if you have any questions about your engine’s emissions
performance.
Guascor Power, S.A.U., Sociedad Inscrita en el Registro Mercantil de Guipúzcoa, Tomo 1195, Folio 178, Sección 8, Hoja SS-3957 - C.I.F. A-48042709
5552656v1
Page 6
Kohler
2.002211.810_A
10-2016
GENERAL INDEX
OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
CHAPTER 1 – SAFETY FEATURES AND PRECAUTIONS
IC-G-D-60-002e_B Safety precautions for KOHLER gas engines 1.1
IC-G-D-60-003e_D Review of compliance with european machinery safety regulations an d "CE" mark requirements 1.9
IC-G-D-00-042e_E Sound press ure level in GAS engines 1.17
IC-G-D-00-043e_F Sound pressure level in the exhaust zone of the GAS engines 1.21
IO-C-M-00-004e_A Guide to environment-friendly waste management during product maintenance and at end of life 1.25
CHAPTER 2 – ENGINE TECHNICAL DESCRIPTION
O&M_2.002211.810_A_10_2016
IC-G-D-00-039e_F Gas engines identification plates and characteristics 2.1.1
IC-G-D-00-253e Emissions plate of Epa certified engines 2.1.9
IC-G-D-00-040e_F Gas engines general description of construction 2.1.11
IC-G-D-00-036e_G Table of technical characteristics in-line FGLD/SFGLD/SFGM/HGM engines 2.1.15
IC-G-D-00-151e Description of the components in one circuit “V” gas engines 2.1.17
IM-G-C-00-002e_F Gaps and wear limits for “V” Gas and Ethanol engines 2.1.25
IM-G-C-00-001e_F Tightening torques for Gas and Ethanol engines 2.1.33
IM-C-C-00-002e_B Tightening torques for commercial bolts & nuts 2.1.37
IC-C-D-00-025e Units conversión 2.1.41
IT-G-A-20-025e One circuit cooling system for gas V - engines 2.2.1
IT-G-A-20-007e_I Gas engines – pressure losses and flowrates 2.2.9
IC-C-D-25-005e_C Description of lubrication system for “V” engines 2.3.1
IT-C-A-25-002e_F Automatic engine oil level controller 2.3.7
IT-C-A-25-045e_B Lube oil level indicator UL 2.3.11
IT-C-A-25-030e_G Kohler engines submerged oil preheating system 2.3.15
IC-C-D-25-006e_B Description of a crankcase Gas recirculation system 2.3.19
2.1 General
2.2 Cooling System
2.3 Lubrication System
2.4 Fuel System
IC-G-D-50-003e EGS 02. Description 2.4.1
IT-G-E-30-001e_B Venturi type carburation - description 2.4.5
IC-G-D-30-040e_A
Specification of Gas supply to tecjet 52 2.4.11
1/3
Page 7
Kohler
Kohler
2.002211.810_A
10-2016
GENERAL INDEX
OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
2.5 Ignition
IC-G-D-33-002e_A Description of the GIS ignition system 2.5.1
O&M_2.002211.810_A_10_2016
IC-C-D-35-002e_C GAS engines intake system 2.6.1
IC-C-D-35-001e_D Air filters 2.6.5
IC-C-D-40-003e_A Oxidative catalytic converters 2.7.1
IC-G-D-40-002e_B Exhaust system and ventilation of the oil sump 2.7.7
IT-C-A-55-001e_J Electric starting 2.8.1
IO-G-M-60-002e_K FG/FGLD/SFGLD/SFGM/SFGRD engines instrumentation 2.9.1
2.6 Intake
2.7 Exhaust
2.8 Starter
2.9 Safety and Control
CHAPTER 3 – HANDLING AND STORAGE INSTRUCTIONS
IM-G-C-00-004e_A Lifting system for SFGLD/SFGM V engine 3.1.1
IO-C-M-00-001e_A Deferred start-up engine inspection and protection 3.1.7
CHAPTER 4 – OPERATING INSTRUCTIONS
IT-G-A-00-011e_C Minimum room temperature for operating Gas engines 4.1.1
IO-C-M-15-002e_A Kohler Engine barring gear operating instructions 4.1.3
IO-C-M-20-001e_D Cooling water quality and treatment 4.1.5
IC-G-D-25-003e_B motoroil 3040 plus lube oil for natural gas-fuelled and ethanol engines 4.1.11
IC-G-D-30-001e_D Fuel specifications for Gas engines. General 4.1.13
IC-G-D-30-021e_B Fuel specifications – Us natural gas 4.1.19
IO-G-M-33-010e Installation and operation manual - Gis ignition unit display 4.1.25
IO-G-T-00-003e Starting and stopping of emergency gas engines 4.1.39
IO-G-M-40-001e_D Gas engine and ethanol carburation 4.1.43
IC-C-D-40-001e_C Emission units conversion 4.1.45
IO-C-M-25-006e_G Oil level indicators 4.1.49
IO-C-M-25-005e_D Automatic oil level controller 4.1.51
IT-G-A-00-008e_A Emissions - related installation instructions 4.1.53
2/3
Page 8
Kohler
Kohler
Kohler
2.002211.810_A
10-2016
GENERAL INDEX
OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
CHAPTER 5 – MAINTENANCE INSTRUCTIONS
O&M_2.002211.810_A_10_2016
IO-G-M-00-060e_B General maintenance of gas engine 5.1.1
IO-G-M-00-061e_C Maintenance of natural gas engine SFGLD 1800 rpm prime 5.1.5
IO-G-M-00-019e_G Maintenance of natural gas engine SFGLD stand-by 5.1.13
IO-G-M-25-001e_G Gas-fueled engine oil servicing instructions 5.2.1
IO-C-M-25-001e_A Oil sampling procedure 5.2.5
IO-C-M-25-004e_A engine oil change instructions 5.2.7
IO-C-M-25-003e_A 180/240/360/480/560 engines centrifugal oil filter maintenance instructions 5.2.11
IO-C-M-25-011e Maintenance of the crankcase gas recirculation system 5.2.13
IO-C-M-25-012e_A Cleaning the oil separator filter of the crankcase gas breather 5.2.17
IO-C-M-00-006e_A engine cylinder compression test 5.2.19
IO-G-M-33-001e_C Conventional spark plug changing and maintenance instructions 5.2.23
IO-G-M-33-002e_F Conventional spark plug replacement criteria in Gas engines 5.2.27
IM-G-C-33-001e_D Conventional spark plug installation instructions 5.2.31
IO-G-M-33-003e_B Check of ignition coils and spark plug wires 5.2.33
IO-G-M-33-007e_L Maintenance of spark plugs. Overview 5.2.35
IO-G-M-33-009e_A Checking the ignition timing 5.2.37
IT-G-E-10-001e_G Adjustment of Gas and Ethanol engine valves 5.2.41
IO-C-M-35-001e_E Air filters. Maintenance 5.2.45
IO-C-M-15-001e_B Damper condition monitoring 5.2.51
IO-C-M-20-002e_G Maintenance of the cooling system 5.2.55
IO-C-M-45-001e_B Maintenance of turbocharger 5.2.61
IO-G-T-35-001e_A Intake safety valve operating and maintenan ce procedure 5.2.65
IO-C-M-20-010e_A Maintenance of intercoolers 5.2.67
IO-C-M-60-004e Maintenance of pick-ups 5.2.71
IO-C-M-55-001e Maintenance of batteries 5.2.73
5.1 Maintenance Procedures
5.2 Description of Maintenance Operations Type E
CHAPTER 6 – TROUBLESHOOTING
IO-G-T-00-001e_B Gas engines troubleshooting 6.1.1
3/3
Page 9
2.002211.810_A
10-2016
SAFETY FEATURES AND PRECAUTIONS
INDEX Chapter 1
OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
CHAPTER 1 – SAFETY FEATURES AND PRECAUTIONS
IC-G-D-60-002e_B Safety precautions for KOHLER gas engines 1.1
IC-G-D-60-003e_D Review of compliance with european machinery safety regulations an d "CE" mark requirements 1.9
IC-G-D-00-042e_E Sound press ure level in GAS engines 1.17
IC-G-D-00-043e_F Sound pressure level in the exhaust zone of the GAS engines 1.21
IO-C-M-00-004e_A Guide to environment-friendly waste management during product maintenance and at end of life 1.25
O&M_2.002211.810_A_10_2016
1/1
Page 10
PRODUCT INFORMATION INDEX DATE
1.1
Dep. 1
IC-G-D-60-002e B
July 2015
SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
O&M_2.002211.810_A_10_2016
TRODUCTION
1. IN
All Kohler engines have been designed in accordance with European Machinery Safety Regulations,
European Directive 2006/42/EC and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-
2. Accordingly, we supply them with the EC Declaration of Conformity and «CE» mark.
The intention has been to supply an intrinsically-safe engine, although the nature of this machine does not rule
out the possibility of potential risks, for which it is necessary to adopt certain safety precautions.
The aim of this document is to inform the users of Kohler equipment on the safety precautions which are
required for handling and operating it adequately.
Engine installations and specially fuel-powered engines must be adapted in all cases to the local regulations.
2. PRELIMINARY OBSERVATIONS
We recommend you to read these safety precaution instructions on receiving your Kohler engine. They are
part of the engine operation and maintenance manual we supply with each engine.
Therefore, we recommend that the manual be kept in perfect condition and readily available to the operator and
those responsible for engine maintenance.
Our Network of Repair Shops is at your disposal to carry out revisions and repairs under the best conditions
and in accordance with the standards established by Kohler.
The use of original spare parts ensures high performance over long periods of operation. These parts have
been manufactured with the same strict quality controls, which were used for the manufacture of the original
equipment.
3. BODILY PROTECTION
CAUTION
Wea
r approved bodily, sight, hearing and respiratory protection. Never wear loose clothing, jewellery or long
hair around the engine.
4. EXHAUST GASES
CAUTION
IC engin
an exhaust discharge pipe so that the exhaust gases are delivered into the outside air. A closed building or
shelter must be adequately vented to provide a steady supply of fresh air.
e exhaust products are toxic and may cause injury or death if inhaled. All engine installations must have
1/8
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PRODUCT INFORMATION
1.2
IC-G-D-60-002e B
INDEX
DATE
July 2015
SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
Dep. 1
O&M_2.002211.810_A_10_2016
5. ENGINE FUELS
CAUTION
If a gas engine has been cranked excessively without starting, shut off the gas fuel supply and continue
cranking the engine to purge the cylinders and exhaust system of accumulated, unburned gas. If you fail to do
this, a spark plug could ignite and cause an explosion.
Engine fuels may ignite or explode. These must be delivered to the engine with proper piping, free from leaks
and designed to resist breakage from vibration.
6. POSITIVE FUEL SHUT-OFF
CAUTION
Some means of positive fuel shut-off should be provided for emergency use.
Pressurised fuels such as natural gas, landfill or digester gas should have another positive shut off valve
(manual, automatic or valve train), other than those in the carburettor or gas pressure regulation equipment.
It is the final responsibility of the user to ensure that the installation is free from fuel or exhaust leakage and
such installation meets all applicable codes.
7. SAFETY GUARDS
CAUTION
IC engines must be provided with guards to protect persons or structures from rotating or heated parts. It is the
responsibility of the engine owner to fit such protection.
8. CRANKCASE GASES
WARNING
All the engines incorporate a crankcase gases vent to relieve pressure that builds up inside as a portion of the
combustion gases flow in through the piston rings (blow by). Make sure the vent pipe is correctly fitted, allowing
free passage of the gases.
2/8
Page 12
PRODUCT INFORMATION
1.3
O&M_2.002211.810_A_10_2016
IC-G-D-60-002e B
INDEX
DATE
July 2015
Dep. 1
SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
9. COOLING SYSTEM PRESSURE CAPS AND CONNECTIONS
CAUTION
Do not remove the pressure caps while the engine is operating or while coolant is hot. The cooling system is
under pressure and severe burns could result from the hot coolant spewing out when the cap is removed. Wait
until the engine and coolants have cooled down before removing caps from the intercooler, thermostat box,
radiator or surge tank. Always replace the weak hoses, lines and fittings.
10. IGNITION SYSTEM
CAUTION
Ignition systems can cause electric shocks. Avoid contacting ignition units and wiring.
A spark plug will fire if the storage capacitor in the electronic ignition module is connected. This may even
happen when the cable is disconnected. When this cable is connected the capacitor will discharge and fire the
spark plug which will ignite any gas which has accumulated in that cylinder. The crankshaft and driven
equipment may rotate, possibly causing personal injury or damage to equipment. Gas which has accumulated
In the exhaust system may also be ignited.
Before reconnecting the cabling of the electronic ignition module, shut off the supply of current.
Protect spark plugs, wires and coils from the rain and snow.
11. GENERATOR SETS
DANGER
The voltage produced by generator sets is dangerous for anyone who touches a part of the electrical system
while this is working. Severe, possibly fatal shock may result from contact. Make sure the generator set is
grounded before operation. Be extremely careful when the unit or surrounding area in damp or wet. When
servicing any part of the electrical system or making any connections, make sure that the main power switch is
off. Clean or service generator only when engine is shut down.
In case of an accident from electrical shock, shut down the generator set at once. If it cannot be shut down, free
the victim from the live conductor.
Avoid direct contact with the victim. Use a dry board, dry rope or any non-conducting implement to free the
victim. If the victim is unconscious, apply artificial respiration and get medical help.
Do not operate the generator set with the ammeter circuit open. Voltage, dangerous to both equipment and
personnel, can be generated in an open secondary circuit of a current transformer.
If the generator set is stopped by operation of safety devices, do not attempt or operate until the cause has
been eliminated.
When the generator set is shut down after operation, disconnect all line switches to all external power load and
parallel circuits.
3/8
Page 13
PRODUCT INFORMATION INDEX DATE
1.4
O&M_2.002211.810_A_10_2016
Dep. 1
IC-G-D-60-002e B
July 2015
SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
12. TIDINESS AND CLEANLINESS
WARNING
Tidine
ss and cleanliness are essential to endure a safe workplace. A tidy workspace with clean catwalks and
well-ordered equipment and tools, allows one to do the job better and is an important factor in accident
prevention.
13. ENGINE AND EQUIPMENT; REPAIR AND SERVICE
CAUTION
Always stop the engine before cleaning, servicing or repairing the engine or driven equipment. Place all controls
in the off position to prevent acc
key. Put a sign on the instrument panel warning that the engine is being s
that all tools and other material are removed from the engine and equipment.
Proper service and repair is important to the safe, reliable operation of the engine and related equipment.
The procedures
repair operations. Some of thes
be used when and as recommended. Anyone who uses a service, repair or installation procedure not
recommended by Kohler must first satisfy themselves thoroughly
that their safety will not be jeopardised by the service methods they selected.
recommended by Kohler in this manual are effective methods for performing service and
idental restarting. If possible, lock all controls in the off position and take the
erviced. Before restarting, make sure
e procedures require the use of specially-designed tools. Special tools should
14. ENGINE FAN BLADES
- Do not operate the engine with the fan bent, broken, modified or damaged in any way.
CAUTION
- Do not operate the engine if the fan contacts or strikes any engine accessory or the radiator shroud or core.
- Do not try to rebalance the fan. Contac
t the supplier if rebalancing is required.
- Ensure that all bolts attaching the fan are securely installed to a torque specified by the engine, vehicle or
boat manufacturer.
- Install the fan s
- Perform all required maintenance on the drive system, as desc
- Do not modify or substitute any parts
Kohler. Take special care not to make modifications which will increase the operating speed of the fan.
o that it is directed correctly towards the radiator.
ribed in this manual.
of the engine without the approval of the Service Department of
4/8
Page 14
PRODUCT INFORMATION INDEX DATE
1.5
O&M_2.002211.810_A_10_2016
Dep. 1
IC-G-D-60-002e B
July 2015
SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
- Install the fan only if the engine has been approved for fan installation. Likewise, install a drive system
defined by Kohler.
- If the fan or drive contains any plastic or rubber component, have the fan and drive inspected by a qualified
mechanic after operation or exposure to excessively high temperatures (air temperature of over 120ºC).
- Replace the fan if indications of excessive corrosion or erosion appear in the fan.
- For rev
prior to operation. Also, inspect the fan prior to operation to ensure that ice and dirt have not accumulated
on the fan to cause potential imbalance of the fan.
- Be sure that all fans, fan drives and belts are properly shielded.
ersible or adjustable pitch fans, make sure the blades are correctly locked in the proper position
15. TURBOCHARGERS
CAUTION
Turb
ochargers are designed specifically for each application. Turbochargers operate at high temperatures,
therefore all inflammable material must be kept away from them. Engines must be shut down and at room
temperature before working on turbochargers or burns will result.
16. ENGINE STORAGE CHEMICALS
DANGER
Protective oils contain a petroleum distillation, which is harmful or fatal if swallowed. Avoid contact with skin,
eyes and clothes. Vapour is harmful and causes irritation of eyes, nose, throat and skin. Use only with adequate
ventilation. Avoid breathing of vapour. Do not take internally. Keep container closed and away from heat.
Always read and observe the <<CAUTION>> labels on the containers. Do not destroy the labels on the
containers.
In general, protective compounds should not be heated over 90ºC. To heat at this temperature, the containers
must be placed in a vessel with hot water. The cover must be removed and a hole must be made in the
container to reduce the danger of explosion. Heating or direct heat is an unnecessary fire risk.
17. FIRE PROTECTION
WARNING
Locate fire
extinguisher inspection and recharging to ensure the fire extinguishing capabilities when required. Consult your
fire extinguisher supplier or insurance engineering for recommendations required for the engine installation. It is
also recommended to have well-identified fire emergency escape routes in all engine installations, in
accordance with regulations.
extinguishers so that they are easily accessible if a fire start. Carefully maintain records of
5/8
Page 15
PRODUCT INFORMATION
1.6
O&M_2.002211.810_A_10_2016
IC-G-D-60-002e B
INDEX
DATE
July 2015
Dep. 1
SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
18. CLEANING SOLVENT
CAUTION
Use approved cleaning solvents in a well ventilated area. Do not breathe fumes as some vapours can be fatal.
Keep away from open flames or sparks. Do not use gasoline or paint thinners or other highly volatile fluids for
cleaning. Always read and observe the <<CAUTION>> labels of containers. Do not destroy the labels on the
containers. Cleaning solvents can cause various kinds of skin irritations.
19. WELDING EQUIPMENT
CAUTION
Welding gas cylinders can explode if damaged. Cylinders must be stored in accordance with manufacturer’s
specifications and applicable safety requirements.
When using acetylene, check valves should be installed between the regulators and hoses to prevent flashback
into the regulators and supply tanks. Flashback could cause the regulators and supply tanks to explode.
Oily and greasy materials must be kept away from oxygen valves, hoses, etc. Oxygen, if combined with such
materials, will cause and explosive reaction.
Always wear protective eyes shields when welding, cutting or watching welding operations. Protective clothing
must be worn. Do not weld or cut near combustible materials.
20. GROUNDING PRECAUTIONS WHEN WELDING
CAUTION
When using an electrical welder on an engine, clip the ground lead as close to the welding site as possible.
Putting the ground lead too far from the welding site may result in arching across the main bearings and fusing
these to the crankshaft.
21. ELECTRICAL TOOLS
CAUTION
Make sure that electrical tools are properly grounded. Wear proper eye protection. Do not work in wet or damp
conditions. Be sure that the tool is in good condition and safety guards are in position. An electric trouble light
must also be grounded. Do not carry electric power tools by the cord. Do not yank the cord when removing from
an outlet. Instead, grasp the plug to remove it from an outlet.
6/8
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PRODUCT INFORMATION
1.7
O&M_2.002211.810_A_10_2016
IC-G-D-60-002e B
INDEX
DATE
July 2015
Dep. 1
SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
22. BATTERIES
CAUTION
Always disconnect the battery ground connection from batteries before performing any work on the engine or
equipment. This will prevent sparks or burns when accidentally shorting an electrical connection.
Never expose batteries to open flame or electric spark. The chemical action of the battery produces
hydrogenous gas which is inflammable and explosive. Do not allow the battery fluid to contact skin, eyes,
clothes or painted surfaces. The electrolyte is a sulphuric acid solution, which could cause serious burns or
damage equipment. Wear eye protection when working with batteries.
23. PRECAUTIONS WHEN USING BOOSTER BATTERIES AND CABLES
Do not attempt to jump start an engine having a frozen battery. The battery may rupture or explode. Before
starting, examine all fill vents on the battery. If ice can be seen, or if the electrolyte fluid cannot be seen, do not
attempt to start with jump cables. Batteries, charged and discharged, should be treated carefully when using
jumper cables.
The following procedures assist in reducing sparks and explosion hazards always present in both batteries
when connecting charged batteries to discharges batteries:
- Turn off all electrical loads. Remove vent caps and lay damp cloth over open vent well of each battery. The
charged booster battery or batteries must have the same voltage capacity as the discharged battery or
batteries.
- The positive post is identified by a <<+>>, pos. and red colour and is larger in diameter than the negative
post.
- The negative post is identified by a <<->> neg, and natural lead colour (grey).
24. COMPRESSED AIR
Compressed air or gases should never be used to clean clothing or your body. Compressed air can pierce the
skin and cause severe and very painful injury.
Never use your hand to check air, gas, or liquid flow rates, or check for leaks. Do not engage in <<horseplay>>
with air, gas or liquid hoses. Observe all applicable regulations as related to compressed gases.
25. INTOXICANTS AND NARCOTICS
CAUTION
Anybody under the influence of intoxicants and/or narcotics is hazard to themselves and other employees.
7/8
Page 17
PRODUCT INFORMATION
1.8
O&M_2.002211.810_A_10_2016
IC-G-D-60-002e B
INDEX
DATE
July 2015
Dep. 1
SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES
26. SAFETY PRACTICES FOR HANDLING ACIDS
Cleaning with acid for certain castings and pieces of equipment is frequent. In handling them, follow these
recommendations:
- Avoid contact with skin, clothing and eyes.
- Descaling operations should be performed away from all fire, spark or other ignition sources.
- Keep acid off of concrete floors because it attacks the lime in the concrete. If solution does get on concrete
surfaces, apply an alkaline solution to neutralise.
- Acids can react with metals to form various gases. Generally, acid solutions on lime scale and rust result in
the formation of harmless carbon dioxide. However, when acids contact aluminium, zinc, cadmium, tin,
sulphur, arsenic or cyanide, poisonous and explosive gases may be generated. When descaling is done in
closed equipment, install proper ventilation to carry the gases away.
- Always store containers closed, placing these in their normal position.
- Be sure that there are no leaks in the vessel being descaled, which will permit solution to leak into opposite
side of equipment. Good practice is to fill the opposite side of the equipment being descaled with water to
level higher than the acid solution.
- Use an acid-proof pump, or an inexpensive, throw-away pump.
- Do not agitate acid solutions with compressed air.
- Applications of acid should be followed by thorough rising, then neutralising with an alkaline solution to
remove all acidic residue, to prevent further action.
- Store acid solutions in either an acid-proof wooden or synthetic rubber lined steel container.
- Check steel equipment to be treated with acid solution for copper or brass fittings or fusible metal plugs. If
possible, dissimilar metals should be removed prior to descaling to prevent electrolytic action which might
interfere with the inhibiting action of acid solution. Do not use acid to descale equipment constructed of
aluminium.
27. ENGINE LIFTING AND HANDLING
- The use of cloth slings is recommended to avoid damaging the equipment with rough movements.
- Assure that the slings do not come into contact with sensitive parts of the equipment.
- Correctly inspect all anchor points so that there is no defective welding, loose screws, etc. that might
jeopardize the lifting of the equipment.
- Verify that all pertinent structures have been inspected, are in good condition, and can support at least the
weight of the equipment plus 10%. If you are not sure, weigh the equipment prior to lifting it.
- Prior to lifting it, be sure to balance the equipment to the maximum, using slings of different lengths if
necessary.
- Keep all personnel away when the unit is in the air.
- Do not lift the equipment further than necessary.
8/8
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PRODUCT INFORMATION INDEX DATE
O&M_2.002211.810_A_10_2016
Dep. 2
IC-G-D-60-003e D
May 2016
REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY
SAFETY REGULATIONS AND "CE" MARK
TRODUCTION
1. IN
This document describes all the design and operative features of our engines and their applications (generating
sets or others) as well as the technical solutions that we have implemented to comply with the current
machinery safety regulations. These include Royal Decree 1435/1992 and subsequent amendments, European
Directive 2006/42/CE and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-2.
Compliance with these is mandatory to be able to issue the Declaration of Conformity with the European
Regulations and to use the "CE" mark.
2. ENGINE DESIGN
The check for compliance with the European Regulations on Machine Safety described in this document applies
to Kohler gas and ethanol engines.
Those engines are mostly developments of their diesel counterparts whose design has passed technical audits
by renowned certification agencies - Lloyd’s Register, Bureau Veritas, Germanischer Lloyd’s, Rina, Det Norske
Veritas, Hellenic Register of Shipping, and others - for approval in marine applications and has been awarded
the ‘type approval' certificate that guarantees the suitability of the basic engineering design.
In designing and manufacturing the engines, Kohler follows risk suppression or reduction criteria,
implementing adequate solutions and adopting the necessary protective measures when it is not possible to
eliminate these risks. In this event, Kohler informs users of any residual hazards due to the incomplete
effectiveness of the protective measures, advising them that they must have specific training and use personal
protective equipment where necessary.
Similarly, in designing and manufacturing the machine as well as in writing the product information, Kohler
bears in mind not only the normal use, but also any reasonably expectable use of the machine.
3. ENGINE ROOM
The engine room or the area surrounding the engine or generating set cannot be rated as a danger zone
under current regulations since the running of the engine will under no circumstances give rise to the release of
solids, liquids or heat in it that could affect the operators' safety.
Despite this, given that the engine’s operation, service or control while running does not require anybody
very close to it, we recommend that operators should stay at a suitable safety distance to prevent the effects
of any fault or unforeseeable failure, should one occur.
Adjustment and fine-tuning operations (valve timing, oil and water level control, etc) are to be undertaken
with the engine stopped. Only qualified and trained personnel must carry out carburetion adjustments
with the engine running according to the set procedures, without putting any of the operators in danger.
4. RISK ANALYSIS
In designing the engines, we adopted technical options or solutions that avoid intrinsic and specific
engine operation hazards.
Nevertheless, due to the very concept of the machine and its operation, there still exist various
unavoidable, though limited hazards, representing a risk for the operator.
1.9
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IC-G-D-60-003e D
May 2016
Dep. 2
REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY
SAFETY REGULATIONS AND "CE" MARK
This section reviews
the design solutions implemented to overcome any machine-specific risks and the
preventive measures against unavoidable risks.
Kohler will not be liable for any injury or damage arising from any use of the engine
other than that described in the instruction manual. Operating the engine beyond its nominal conditions (e.g. in
terms of power, ignition advance, mixture strength - carburetion, etc) can have serious consequences for the
user or even put the user's life at risk and cause extensive material damage.
4.1. MATERIALS AND PRODUCTS
The materials and products used for the construction and operation of the machine do not involve any health or
safety hazard as long as operators follow the user instructions and current regulations.
4.2. EQUIPMENT DRIVES
The drive systems are safe and reliable, with clearly identified and visible controls, including adequate alarms as
well as normal and emergency stop devices.
4.3. MECHANICAL HAZARDS
The equipment supplied has been designed and built to offer sufficient stability under the planned operating
conditions. Its components are designed for appropriate resistance in operation. Product information sheets
specify the necessary inspection and maintenance programmes for safety’s sake.
We design and manufacture the moving parts of the engine to avoid any risk. Therefore they incorporate guards
or protective systems impeding physical contact that would cause injuries or accidents. Drive components
(pulleys, belts, gears, etc) have covers that can be fixed or are movable depending on the frequency of
servicing tasks. All protective devices are made solidly and resistant.
4.4. ELECTRICAL HAZARDS
The engines’ design, construction and equipment prevent or ensure possible prevention of all electrical hazards.
Refer to the “Electrical installation” section. The engines also have static elimination systems.
4.5. FIRE, EXPLOSION AND HIGH TEMPERATURE HAZARDS
We have taken precautionary measures to avoid injuries caused by hot parts or materials through physical
contact or remotely. We also addressed the risk of flying hot matters and avoided fire and overheating hazards
originating in the engine.
Various types of fluids of varying properties circulate through the engine at varying temperatures.
4.5.1. COOLING WATER
By design, all the connections in the water circuit are fitted with mechanical seals and/or bushed systems with
ethylene propylene O-rings, suitable for the high temperature of the engine coolant in the main system (120 ºC)
and in the auxiliary circuit (90 ºC). Therefore no rubber couplings are used.
4.5.2. LUBRICATING OIL
The oil circuit has been designed fully integrated into the engine so that the only outgoing pipes are those to and
from the oil cooler. Sealing of all the tubes is through mechanical seals or bushed systems with Viton O-rings,
avoiding the use of rubber couplings by all means.
1.10
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O&M_2.002211.810_A_10_2016
IC-G-D-60-003e D
INDEX
DATE
May 2016
Dep. 2
REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY
SAFETY REGULATIONS AND "CE" MARK
4.5.3. FORCED INDUCTION
In the supercharging circuit (downstream of the turbocharger), the components are sealed is mechanically with
Viton O-rings. Rubber sleeves and other materials have been totally discarded.
4.5.4. MANIFOLDS AND EXHAUST PIPE
To limit leak risks, the engine exhaust manifolds are mechanically sealed with special metal-reinforced joints.
For the purposes of protecting the operators from accidental contact, we have designed a cooled exhaust
manifold with the engine cooling water circulating outside and around it so that the temperature on the exhaust
manifold surface, otherwise 400 to 500 ºC, falls to the coolant temperature levels of 80 to 90 ºC.
As for the turbocharger, the turbine casing (exhaust side) is also very hot and cannot be cooled but is protected
with a heat-insulating blanket (or jacket) limiting the surface temperature to less than 90 ºC. This solution also
applies where the engine application requires the use of hot (uncooled) exhaust manifolds.
A similar type of protection covers that part of the exhaust elbow or pipe extending to the connecting flange on
the hose for connection to the external exhaust pipe. The installation project must protect this exhaust pipe.
When supplying the installation, we check for any contact with this piping and, where appropriate or for exhaust
heat recovery if desired, we protect the pipe with a stainless steel lined heat-insulating blanket.
4.6. VIBRATION
Engine vibrations do not affect operator safety, although they could be transmitted through the engine mounting
to other machines or to the building, causing a nuisance for people in the neighbourhood. Engines for
applications where structure-borne vibrations are likely to occur will be isolated from their support by elastic
vibration absorbers.
We also use flexible elements to connect all the utilities (water, fuel, oil, etc) to the outside of the engine.
4.7. NOISE
Noise generation is inherent to the engine and is generally inevitable although design approval is conditioned to
a sustainable sound level when adequate and necessary means of protection are used.
Ear protection is necessary for all the people present in the engine room when the engines are running.
Therefore, at the entrance to the engine room, there must be a clear and visible warning of the obligation for the
operators to wear ear protection.
No type of ear protection is specified, as the certified personal protective equipment usually available on the
market is considered suitable.
As regards noise outside the engine room (environmental noise pollution), it is necessary to install - and we do
install in all cases - adequate exhaust silencers to meet the local or environmental rules and regulations in force
where the engines operate.
4.8. ELECTRICAL INSTALLATION
The engine’s electrical installation consists of one terminal box for the connection of 24 V DC and 220 V, 400 V,
480 V, etc, devices, including sensors, contacts, etc. This terminal box and the wiring for these devices comply
with the low voltage wiring regulations and Directive 73/23/EEC as amended by Directive 93/68/EEC. There is a
switch on the front of this box for immediately stopping the engine in an emergency.
1.11
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PRODUCT INFORMATION
O&M_2.002211.810_A_10_2016
IC-G-D-60-003e D
INDEX
DATE
May 2016
REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY
SAFETY REGULATIONS AND "CE" MARK
4.9. FUEL SYSTEM
GAS
The gas system design always conforms to the applicable regulations (UNE 60.620) and comprises the
following elements:
ERM. Gauge and meter panel built to the applicable standard for this type of engine to ensure a gas
supply under the set pressure conditions.
VALVE TRAIN. Set of elements comprising a hand-operated shut-off valve, gas filters, a pressure control
gauge, a double normally-closed solenoid valve to stop the gas flow to the engine and a venting line for
leaks control or electronic leak control, all consistent with the standard specifications.
CONNECTIONS TO THE ENGINE, by DIN flanges and homologated hoses in all cases.
ENGINE-MOUNTED PRE-CARBURATION PIPING designed with a minimum of development and
connections. In any case, the pipes are made to the installer's standards and checked for leaks during the
engine tests.
POST-CARBURATION AIR/GAS MIXTURE PIPING. The whole circuit has been mechanically sealed
with Viton O-rings (all rubber or silicone couplings have been suppressed).
ETHANOL
The ethanol fuel system includes:
ERM. Gauge and meter panel built to the applicable standard for this type of engine to ensure an ethanol
supply under the set pressure conditions.
VALVES Set of elements comprising a hand-operated shut-off valve, ethanol filters, a control pressure
gauge and a double normally-closed solenoid valve to stop the ethanol flow to the engine, all in
accordance with the specifications as required by regulation.
CONNECTIONS TO THE ENGINE in all cases by DIN flanges, NPT couplings and authorised hoses.
ENGINE-MOUNTED PIPING designed with a minimum of development and connections. In any case, the
pipes are made in accordance with standards and checked for leaks during the engine test phase. To
ensure sealing and avoid any incident, the solution adopted includes double layer hoses using a stainless
braid without any type of elastomer that deteriorates on contact with ethanol.
Both fuel systems (gas and ethanol) come equipped with the following additional safeguards:
"BACKFIRING" or "DETONATION" PROTECTION. In a gas engine, backfiring may happen when burning
of the fuel mixture takes place in the intake manifold because damaged valves do not seal the
combustion chamber hermetically. Detonation occurs if the mixture strength varies out of control or when
the mixture self-ignites in contact with hot surfaces.
Two forms of protection or safeguards have been adopted as a direct protection against these
phenomena. The mechanical resistance of the equipment (as regards intake manifold joints, ribs, etc) has
been increased with respect to the normal design specification (diesel type) and two pressure-relief
valves have been installed in the intake manifold to permit a pressure leak while preventing any overload
of the manifolds.
Indirect protection is provided by the engine's own control and regulating systems which have been
designed to protect the engine against erratic or abnormal operation.
Dep. 2
1.12
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4.10. BLOW-BY GASES
O&M_2.002211.810_A_10_2016
PRODUCT INFORMATION INDEX DATE
IC-G-D-60-003e D
May 2016
Dep. 2
REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY
SAFETY REGULATIONS AND "CE" MARK
Because it is impossible to have the combustion c
hamber completely sealed, combustion gases always
accumulate in the crankcase and can give rise to oil splashing outside due to overpressure in the crankcase. To
prevent this occurrence, all the engines come complete with an explosion relief valve to expel those gases,
which are fed back after filtering into the engine intake system on environmental protection grounds.
4.11. EXHAUST FUMES
The emission of exhaust fumes is intrinsic to the engine’s function and is thus inevitable. There are clear and
specific instructions for installing exhaust gas piping to eliminate the risk of contaminating the engine room.
Those instructions specify the requisites for the exhaust piping layout, how to calculate the pipe diameters,
standards for the placement of expansion joints, etc.
4.12. MAINTENANCE
Maintenance tasks must be undertaken with the machine idle. The maintenance, adjustment, lubrication and
upkeep points lie outside dangerous areas. Staff can work safely and at ease and the reasons for their
intervention are limited.
4.13. INFORMATION
Product information necessary for using the equipment is clear, concise and easy to understand. The machines
include alarm systems that report any malfunction of the machine and warn exposed persons of possible risks.
There are signalling devices (dial gauges, control panels, etc) on the equipment as well as warning signs
informing of potential non-evident persistent hazards through icons that everybody understands.
All engines are delivered with a minimum of safety devices and operational controls and although their primary
function may not be to protect operators, they do protect them indirectly by preventing malfunctions or
inadequate operation.
The following information is legibly and indelibly available on each machine: nameplate (manufacturer's name
and address, model, serial number, year of manufacture, power, fuel gas quality and pressure requirements),
and specific “CE” mark tag. The product information also contains all the necessary instructions for the safe
operation of the machine.
On the non-moving parts of the engine there are strong lugs for the safe handling of the engine with
conventional lifting equipment. The product information also clearly states the engine’s weights needed for tis
suitable transport.
4.14. INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUALS
Each machine has its instruction manual containing a reminder of the data required for the marking, except the
serial number, as well as the instructions for easy maintenance, conditions of intended use, instructions for safe
commissioning, operation, handling (including information about the machine’s weight), installation, assembly,
disassembly, adjustment, maintenance (preventive and corrective), and counter-indications.
Kohler has prepared an instruction manual in Spanish, English, French, German
and Italian. This manual must be kept close to the machine, when put into service. The mechanic's handbook,
intended for specialist staff who source from the manufacturer, is available in English or Spanish. According to
the standing regulations, to use the “CE” mark, it is compulsory to have the engine instruction manuals available
in the official language of the member state in which the engine operates. Fulfilment of these regulations will be
achieved by translating the current Installation, Operation and Maintenance Instruction Manuals in pace with the
sales of our engines to the various countries in the European Union.
1.13
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PRODUCT INFORMATION INDEX DATE
O&M_2.002211.810_A_10_2016
Dep. 2
IC-G-D-60-003e D
May 2016
REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY
SAFETY REGULATIONS AND "CE" MARK
The instruction manuals include all necessary drawings and diagrams to install, operate, maintain and inspect
the machine and check it for correct operation, and make any repair, if needed, in addition to other
relevant recommendations, especially in relation to safety issues. Kohler has prepared the following manuals
in compliance with the Machinery Safety Directive:
- Installation Manual (installation and start-up).
- Operation and Maintenance Manual (maintenance, inspection, safety and correct operation testing).
- Spare Parts Manual (list of spare parts for the equipment).
- Mechanic's Manual (specialist inspection and repair of the equipment).
Catalogues and other documents used to present the machine are consistent with the instruction manuals as
regards safety. The Installation Manual provides assembly and installation recommendations to reduce noise
and vibration (dampers, foundations, etc). Data on the machine’s airborne noise appear in the Instruction
Manuals.
Engines are installed according to a specific installation manual for each application. This manual includes:
- General engine dimensions drawing.
- Engine peripherals drawing (includes information for installing all the necessary peripherals for engine
operation - water, oil, fuel, exhaust, etc).
- Specific installation instructions for each peripheral.
- Specific instructions for engine complements or optional and additional devices (not mandatory).
The operation and maintenance manuals for each engine are written so the operator has readily available
information for:
- The identification of the machine and its components.
- Instructions for proper adjustment and start-up.
- Operational instructions.
- Maintenance instructions (frequency of maintenance operations). These are of major importance as a
direct safety element to insure proper engine condition and operation.
5. SAFEGUARDING AGAINST MALFUNCTION
The monitoring and safety systems, that verify the engine operating condition through the measurement of its
major parameters, activate PREVENTIVE warning signals when current values exceed the predetermined
setpoints or immediately STOP THE ENGINE if the alarm threshold is reached.
In any event, in prevision of any potential monitoring system failure, all gas engines are fitted with a
communication and junction box connected to the electric control panels. This box, placed ON THE ENGINE,
includes an EMERGENCY STOP SWITCH for the deliberate and immediate stoppage of the engine.
In all cases there is also an engine-mounted EMERGENCY STOP LEVER which, once operated MANUALLY
and deliberately, blocks the air/gas supply to the engine immediately, causing the engine to stop at once.
1.14
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PRODUCT INFORMATION
O&M_2.002211.810_A_10_2016
IC-G-D-60-003e D
INDEX
DATE
May 2016
Dep. 2
REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY
SAFETY REGULATIONS AND "CE" MARK
6. SAFETY PRECAUTIONS
In all instances, together with the engine operation and maintenance documentation, we deliver Product
Information IC-G-D-60-002e “Kohler gas engine safety precautions” which describes preventive measures for
handling our engines and their environment.
7. CONCLUSION
The above review allows us to conclude that Kohler engines have been designed in full awareness of and
in compliance with the machinery safety regulations requirements, as specified in Directive 2006/42/EC
and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-2. Consequently, it is right to
issue the relevant Declaration of Conformity and to use the "CE" mark that guarantees it.
Related product information:
- IC-G-D-00-040e: "General gas engines construction description.”
- IC-L-D-00-001e: "General ethanol engines construction description."
- IC-G-D-60-002e: "Safety precautions for engines."
All certificates that support the statements and conclusions in this report have been documented and submitted
to external auditing.
1.15
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Page 25
PRODUCT INFORMATION
1.17
IC-G-D-00-042e E
INDEX
SOUND PRESSURE LEVEL IN GAS ENGINES
DATE
March 2015
Dep. 2
O&M_2.002211.810_A_10_2016
1. INTRODUCTION
The purpose of this information is to define the noise emission levels in Kohler gas engines.
2. ACOUSTIC DEFINITIONS
Decibel
Logarithmic unit that relates an energy magnitude with another, similar, magnitude accepted as a reference.
Sound power
Energy that a sound source emits to the surrounding medium by time unit.
Sound pressure
Atmospheric pressure variations at one point, produced by the propagation of a sound wave.
3. NOISE EMISSION AT 1200 RPM
The following table shows the sound pressure distribution in octave frequency bands and the total sound level
with the engine running continuously at 1200 rpm and at 100% power.
ENGINES F/SFGLD 180 240 360 480 560
125
250
500
1000
2000
BANDS (Hz)
4000
LpA IN FREQUENCY
LpA, dB(A)
-70
82
84
81
76
59
73
79
85
83
77
-69
76
82
83
79
66
70
76
81
80
73
71
79
81
83
84
79
88 88 87 85 89
HGM ENGINES 560
125
250
500
1000
2000
BANDS (Hz)
4000
LpA IN FREQUENCY
LpA, dB(A)
71
77
79
81
88
83
90
1/3
Page 26
PRODUCT INFORMATION
1.18
IC-G-D-00-042e E
INDEX
SOUND PRESSURE LEVEL IN GAS ENGINES
DATE
March 2015
Dep. 2
O&M_2.002211.810_A_10_2016
Notes
- Sound power levels obtained as per the ISO 9614-2 standard.
- Sound pressure levels measured at 1 m from the engine, calculated as per the UNE-EN ISO-11203:1996
standard.
- The uncertainty of the results is for class 3 determinations with a maximum standard deviation of =
4
dB(A).
4. NOISE EMISSION AT 1500 RPM
The following table shows the sound pressure distribution in octave frequency bands and the total sound level
with the engine running continuously at 1500 rpm and at 100% power.
F/SFGLD/SFGM
ENGINES
125
250
500
1000
180 240 360 480 560
-73
83
87
72
82
87
90
70
81
86
88
73
83
88
90
76
92
89
89
2000
BANDS (Hz)
4000
LpA IN FREQUENCY
LpA, dB(A)
84
79
89
86
86
80
89
82
89
85
90 95 92 95 97
HGM ENGINES 240 420 560
125
250
500
1000
2000
BANDS (Hz)
4000
LpA IN FREQUENCY
LpA, dB(A)
73
83
85
88
92
89
71
81
84
87
90
89
73
83
85
88
92
89
96 94 96
Notes
- Sound power levels obtained as per the ISO 9614-2 standard.
- Sound pressure levels measured at 1 m from the engine, calculated as per the UNE-EN ISO-11203:1996
standard.
- The uncertainty of the results is for class 3 determinations with a maximum standard deviation of =
4
dB(A).
2/3
Page 27
PRODUCT INFORMATION
1.19
IC-G-D-00-042e E
INDEX
SOUND PRESSURE LEVEL IN GAS ENGINES
DATE
March 2015
Dep. 2
O&M_2.002211.810_A_10_2016
5. NOISE EMISSION AT 1800 RPM
The following table shows the sound pressure distribution in octave frequency bands and the total sound level
with the engine running continuously at 1800 rpm and at 100% power.
F/SFGLD/SFGM
ENGINES
125
250
500
1000
2000
BANDS (Hz)
4000
LpA IN FREQUENCY
LpA, dB(A)
HGM ENGINES 240 420 560
125
180 240 360 480 560
-76
88
91
87
83
70
86
84
89
87
83
-74
90
85
87
82
70
84
84
88
89
83
73
87
85
87
91
86
94 94 93 93 95
67
--
70
250
500
1000
2000
BANDS (Hz)
4000
LpA IN FREQUENCY
LpA, dB(A)
77
80
88
91
87
74
88
83
90
87
84
82
86
92
88
94 94 95
Notes
- Sound power levels obtained as per the ISO 9614-2 standard.
- Sound pressure levels measured at 1 m from the engine, calculated as per the UNE-EN ISO-11203:1996
standard.
- The uncertainty of the results is for class 3 determinations with a maximum standard deviation of =
4
dB(A).
3/3
Page 28
PRODUCT INFORMATION
IC-G-D-00-043e F
INDEX
DATE
July 2016
Dep. 2
SOUND PRESSURE LEVEL
IN THE GAS ENGINES EXHAUST AREA
O&M_2.002211.810_A_10_2016
1. INTRODUCTION
The purpose of this information is to define the noise emission levels in the Kohler gas engine exhausts.
2. ACOUSTIC DEFINITIONS
Decibel
Logarithmic unit that relates an energy magnitude with another, similar, magnitude accepted as a reference.
Sound power
Energy that a sound source emits to the surrounding medium by time unit.
Sound pressure
Atmospheric pressure variations at one point, produced by the propagation of a sound wave.
3. NOISE EMISSION AT 1200 RPM
The following table shows the sound pressure distribution in octave frequency bands and the total sound level
with the engine running continuously at 1200 rpm and at 100% power.
F/SFGLD ENGINES 180 240 360 480 560
63
125
250
500
1000
BANDS (Hz)
2000
LpA IN FREQUENCY
4000
LpA, dB(A)
94
106
106
112
108
109
109
117 120 121 124 121
96
109
113
115
111
113
112
96
109
113
115
112
113
114
94
111
112
119
116
117
116
98
109
112
117
113
113
114
HGM ENGINES 560
63
125
250
500
1000
BANDS (Hz)
2000
LpA IN FREQUENCY
4000
LpA, dB(A)
99
109
115
116
114
114
116
122
1.21
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PRODUCT INFORMATION
IC-G-D-00-043e F
INDEX
DATE
July 2016
Dep. 2
SOUND PRESSURE LEVEL
IN THE GAS ENGINES EXHAUST AREA
Notes
- Sound power levels obtained as per the ISO 9614-2 standard.
- Sound pressure levels measured at 1 m from the engine, calculated as per the UNE-EN ISO-11203:1996
standard.
- The uncertainty of the results is for class 3 determinations with a maximum standard deviation of =
dB(A).
O&M_2.002211.810_A_10_2016
4
4. NOISE EMISSION AT 1500 RPM
The following table shows the sound pressure distribution in octave frequency bands and the total sound level
with the engine running continuously at 1500 rpm and at 100% power.
F/SFGLD/SFGM ENGINES 180 240 360 480 560
63
125
250
500
1000
BANDS (Hz)
2000
LpA IN FREQUENCY
4000
LpA, dB(A)
97
118
124
113
112
110
106
126 128 129 130 129
99
121
127
116
115
114
109
HGM ENGINES 240 420 560
63
125
250
500
1000
BANDS (Hz)
2000
LpA IN FREQUENCY
4000
LpA, dB(A)
100
121
129
116
116
115
112
130 130 130
105
119
129
116
115
113
111
Notes
- Sound power levels obtained as per the ISO 9614-2 standard.
100
121
126
119
117
115
110
102
122
128
122
119
117
112
98
124
125
124
121
119
111
102
121
125
122
118
115
109
- Sound pressure levels measured at 1 m from the engine, calculated as per the UNE-EN ISO-11203:1996
standard.
- The uncertainty of the results is for class 3 determinations with a maximum standard deviation of =
dB(A).
1.22
4
2/3
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PRODUCT INFORMATION
IC-G-D-00-043e F
INDEX
DATE
July 2016
Dep. 2
SOUND PRESSURE LEVEL
IN THE GAS ENGINES EXHAUST AREA
O&M_2.002211.810_A_10_2016
5. NOISE EMISSION AT 1800 RPM
The following table shows the sound pressure distribution in octave frequency bands and the total sound level
with the engine running continuously at 1800 rpm and at 100% power.
F/SFGLD/SFGM ENGINE 180 240 360 480 560
63
125
250
500
1000
BANDS (Hz)
2000
LpA IN FREQUENCY
4000
LpA, dB(A)
99
128
128
120
115
112
105
132 135 135 136 135
101
131
131
123
118
116
108
102
131
131
126
119
116
110
99
127
134
130
123
119
112
102
125
134
128
120
115
110
HGM ENGINES 240 420 560
63
125
250
500
1000
BANDS (Hz)
2000
LpA IN FREQUENCY
4000
LpA, dB(A)
102
131
133
122
119
117
110
136 135 137
106
129
133
123
117
114
111
103
125
136
127
121
117
113
Notes
- Sound power levels obtained as per the ISO 9614-2 standard.
- Sound pressure levels measured at 1 m from the engine, calculated as per the UNE-EN ISO-11203:1996
standard.
- The uncertainty of the results is for class 3 determinations with a maximum standard deviation of =
dB(A).
4
1.23
3/3
Page 31
PRODUCT INFORMATION INDEX DATE
1.25
Dep.2
IO-C-M-00-004e A
February 2012
GUIDE TO ENVIRONMENT-FRIENDLY WASTE MANAGEMENT
DURING PRODUCT MAINTENANCE AND AT END OF LIFE
O&M_2.002211.810_A_10_2016
1. INTRODUCTION
te generated during the maintenance of Kohler equipment, or at the end of their useful life, demands
Was
environmentally correct management. This guide establishes adequate environment-friendly waste management
procedures that aim at keeping the environmental impact as low as possible and at boosting waste recycling
and valorisation processes.
It is thus essential to disassemble, handle and manage the parts, components and waste removed from Kohler
machines according to the waste management procedures that legislation prevailing at the equipment’s
operating site might provide from time to time.
Most components of the machines are ferrous and non-ferrous materials (scrap) that are usable as raw materials
in the iron and steel industry. All other non-reusable waste products will be disposed of to landfill sites. When
performing the a.m. disassembling, removal and handling operations, it is necessary to bear in mind the impact
they may have on the environment, including but not limited to contamination resulting from inadequate
arrangement of stored supplies or from ground pollution at the place where said operations are carried on.
The environmental impact that improper handling of waste products may cause further originates in machines
containing hazardous substances that must be considered throughout the operations said ma chines undergo.
2. DECONTAMINATION AND DISASSEMBLY
ATTENTION
Maintena
and are classified as hazardous waste (see further below). Only if it is planned to reuse the complete engine
block is it admissible to keep it lubricated, omitting to extract oil.
The area assigned to decontamination operations shall comprise pollution prevention systems against accidental
spillage while handling the machines (sealed collection boxes) and (whenever possible) grease separation and
settling systems. Likewise, provisions shall be made to store decontamination process waste under cover and
separately in adequate containers, such as containers for batteries or sealed tanks for each type of liquid waste
(fuels, oils, coolants, etc.). Those tanks must have individual retention basins per type of waste, or similar
systems to ensure possible overflow containment.
All collected dangerous waste shall be forwarded, separately and subject to prior acceptance, to authorised
hazardous waste managers.
Decontaminated machines, which thus rank as NON-HAZARDOUS WASTE, shall undergo the following process:
disassembly and sorting of components and special waste products capable of reuse or recycling. This type of
waste includes metallic components that contain copper, aluminium and magnesium, electric parts and plastic
items.
It will thus be necessary to do the following: remove the battery as soon as possible, extract fuel and all other
fluids, materials and components classified as hazardous waste, discharging them into their respective, properly
tagged containers. Draining all the fluids must be carried on in the appropriate manner to minimise hazardous
waste generation at subsequent pressing and fragmentation processes and to make recycling easier. The fluid
removal means (funnels, drums, pumps, etc.) shall be assigned to one single duty exclusively and be duly
identified and tagged to prevent using them for other duties. For instance, gas oil extracting means shall differ
from lube oil draining equipment.
nce staff shall decontaminate the machine, stripping it of all the parts that contain hazardous substances
1/5
Page 32
PRODUCT INFORMATION
1.26
IO-C-M-00-004e A
INDEX
DATE
February 2012
Dep.2
GUIDE TO ENVIRONMENT-FRIENDLY WASTE MANAGEMENT
DURING PRODUCT MAINTENANCE AND AT END OF LIFE
O&M_2.002211.810_A_10_2016
3. STAFF TRAINING
Operators in charge of decontamination and disassembly shall receive adequate information and training to
ensure they qualify to do the jobs involved. Besides maintenance of the equipment to prevent contamination in
the event of accidental spillage or leakage, training shall cover safety procedures in relation to: (i) the storage and
labelling of hazardous chemicals (pollutant, inflammable, toxic, harmful, etc.); (ii) pouring inflammable liquids into
other containers; (iii) manual handling of loads (carrying and lifting); (iv) correct use of personal protective
equipment; and (v) correct use of extinguishers and fire-fighting systems.
4. DECONTAMINATION, WASTE PROCESSING AND MANAGEMENT METHODS
Another important issue refers to the choice of the waste products’ final destination. As is the case for any other
type of waste, this selection shall comply with the established hierarchical process structure:
1. Reduce, whenever possible, the amount of waste through good operating practices. That will avoid spillage,
leakage, etc., which in turn will result in less soaked cloths, contaminated absorbent products, etc.
2. Recycle. Where reuse is not feasible, it will be necessary to look for processing methods enabling to reincorporate the waste products into the production chain (scrap, retreading of tyres, etc.).
3. Valorise. If no other use is possible, energetic valorisation may be an option.
4. Dump. The portion of waste for dumping shall always be the lowest possible.
4.1. HAZARDOUS WASTE
DANGER
Fuels, motor oils, coolants and antifreeze products, batteries, oil filters and fuel filters are items classified as
hazardous waste, which can be present in the machines at the end of their useful life and must be removed
during the decontamination phase.
There are various methods available to remove and extract fluids from the machines: gravity draining, pumping
out, etc. The simplest method consists in suction pumping any waste fluid.
To do so, open the fluid containing tank or cavity and install the fluid recovery unit in the adequate position. You
must obligatorily use one such unit per type of fluid. Make sure it is properly identified and tagged to prevent cross
contamination of the different fluids to be drained. It is advisable for you to use a unit fitted with a large funnel and
telescopic pipe or another similar vertically adjustable system.
Pumping with a pneumatic pump will be the method for discharging waste fluid from the recovery unit tank to the
storage vessel or container pending collection by the authorised waste manager. As an alternative to the a.m.
mobile recovery unit, it is possible to use a funnel, connecting it to a drum through a hose.
4.1.1. RECOMMENDED HANDLING METHODS
Lead-Acid Battery. Selective disposal of batteries implies eliminating such contaminants as sulphuric acid and
lead from the fragmentation waste products and recovering such materials as metals and plastic. Batteries are
classified as corrosive. Decontamination: Remove the battery from its housing; cut the connection wires if the
terminals are rusty and hard to detach. Check for leaks. Always make sure you have a battery acid neutraliser
(e.g. sodium bicarbonate) within reach and ready for use in case of spill.
Fuels: They include petrols, gas oil and ethanol that are classified as inflammable and harmful. Decontamination:
Empty the fuel tank. Pour waste fuel or non-reusable fuel into adequate and properly tagged tanks or vessels.
Store them separately and forward them separately to the authorised waste manager.
2/5
Page 33
PRODUCT INFORMATION INDEX DATE
1.27
Dep.2
IO-C-M-00-004e A
February 2012
GUIDE TO ENVIRONMENT-FRIENDLY WASTE MANAGEMENT
DURING PRODUCT MAINTENANCE AND AT END OF LIFE
O&M_2.002211.810_A_10_2016
Used motor oils: These fluids pollute soils; they are leaching-toxic to surface and underground waters.
Therefore, correct management is essential to avoid transferring contamination to the receiving environments.
Motor oils are classified as toxic and hazardous in addition to inflammable. Toxic additives are present in their
composition and they can be spoiled and contaminated by combustion by-products or materials they have been in
contact with. Decontamination: Open and remove the filling plugs and crankcase drain caps allowing oil to flow
by gravity or pumping. Instead of an Oil Recovery unit, you may use a funnel connected to a container through a
hose, complete with an antidrip tray.
Whenever possible, before removing motor oil, it is best to operate the engine for a certain time; this will improve
draining, especially in case of low ambient temperature.
Antifreeze. Coolants for the engine cooling system consist of a water and antifreeze mixture. Antifreeze products
generally are glycols or s
products. Dec
ontamination: Visually inspect antifreeze to determine whether it is reusable or it is waste fluid.
imilar polyalcohols (ethylene glycol or propylene glycol). They are classified as toxic
Install the available collecting system appropriately. Release or cut the sleeves to enable complete draining of the
engine cooling circuit. This will be easier if you open the filling plug and drain caps. Waste antifreeze is recyclable
for marketing again, either through an authorised waste manager or at the operating site itself, using the
distillation, filtration, ultrafiltration or ion exchange techniques.
Used oil filter. Decontamination: The most efficient method for removing oil from the filter consists in taking off
and empty
ing the filter, allowing oil to drain on the funnel of the collecting system or on a drip pan, before
squeezing the filter to facilitate draining. An alternative procedure consists in carefully drilling the filter cap with an
adequate (spark resistant) tool and setting it (with the hole downwards) on a collecting vessel or drip pan for 24
hours at least. Store the filter in an ad hoc container until you can forward it to the authorised waste manager.
Fuel filter. Decontamination: The most efficient method for removing fuel from the filter consists in taking off and
emptying the filter, allowing fuel to drain on the funnel of the collecting system or on a drip pan, before squeezing
the filter to drain fuel completely. An alternativ
e procedure consists in removing the filter, carefully drilling the filter
cap with an adequate (spark resistant) tool and setting it upside down, with the hole downwards, on a collecting
vessel (drip pan, funnel, etc.) for 24 hours at least. Store the filter in an ad hoc container until you can forward it
to
the authorised waste manager.
Asbestos. Asbestos is classified as a toxic and hazardous (carcinogenic) substance. Presently, there is a
ban put on its marketing and use. Kohler machines are free from asbestos.
Decontamination process waste and handling waste. Management of hazardous waste resulting from the
decontamination process shall conform to the following. Absorbent products: Keep the absorbent products used
to collect spills and leaks in adequate containers until you can forward them to the relevant waste manager.
Empties: Non-reclaimable empty drums that contained hazardous substances shall be forwarded to the
authorised manager. Contaminated rags: put them in an ad hoc container and forward them to the authorised
waste manager.
4.2. NON-HAZARDOUS WASTE
Remove all reusable parts and components from the machine, as well as any items that can be disassembled
and recycled through scrap reclamation.
3/5
Page 34
PRODUCT INFORMATION
1.28
IO-C-M-00-004e A
INDEX
DATE
February 2012
Dep.2
GUIDE TO ENVIRONMENT-FRIENDLY WASTE MANAGEMENT
DURING PRODUCT MAINTENANCE AND AT END OF LIFE
O&M_2.002211.810_A_10_2016
5. WASTE MANAGEMENT
Effective management of the Hazardous Waste Products deriving from machine maintenance and end of life
starts with appropriate packaging, labelling and storage at the operating site.
The producers of hazardous waste are under an obligation to refrain from pouring waste liquids into sewer
systems, septic tanks, etc., as well as to use different methods and systems for collecting and processing each
type of waste in order to avoid cross contamination, and to avoid mixing different classes of waste.
Packaging of Hazardous Waste. The containers and their seals shall be so designed and developed as to
prevent leakage whatsoever. They shall be made of materials resistant to the type of waste they are to hold.
Those constructional materials shall not be prone to hazardo us combinations with the waste products.
Labelling of Hazardous Waste. Containers or packagings shall bear a firmly secured, clear, readable and
indelible label stating the waste identification code, nature of waste intrinsic hazards, name and address and
phone number of the owners of the waste products, date packed.
WASTE OIL
Waste identification code:
Q7//R1//L8//C51//H5/6//A241//B0019
CER: 13 02 05
Details of the owners of waste
Name:
Address:
Telephone nr.:
T
POISON
Date packed:
Hazardous Waste Waste Identification Code CER Pictogram
Used oil Q7 //R_//L8//C51//H5/6//A935/B0019 130205 Toxic – T
Antifreeze Q7 //D-R_//L20//C51//H6//A935/B9711 160114 Toxic – T
Lead-acid batteries Q6 //R_//S37//C18/23//H8//A935/B0019 160601 Corrosive – C
Gas oil Q7 //R_//L9//C51//H38//A935/B9711 130701
Ethanol Q8 //R13 //L9//C51//H3A//A870/B0019 130703
Oil filters Q6 //R_//S35//C51//H5//A935/B9711 160107 Harmful – Xn
Contaminated cloths and
absorbent products
Fuel filters Q6 //D_//S35//C51//H5//A935/B9711 160121 Harmful –Xn
Q5 //D_//S40//C51//H5//A935/B9711 150202 Harmful –Xn
Flammable - F
Flammable - F
Harmful – Xn
Toxic – T
Contaminated metal containers Q5 //R_//S36//C41//H5//A935/B9711 150110 Harmful –Xn
Contaminated plastic containers Q5 //D-R_//S36//C41/51//H5//A935/B9711 150110 Harmful –Xn
4/5
Page 35
PRODUCT INFORMATION
1.29
IO-C-M-00-004e A
INDEX
DATE
February 2012
Dep.2
GUIDE TO ENVIRONMENT-FRIENDLY WASTE MANAGEMENT
DURING PRODUCT MAINTENANCE AND AT END OF LIFE
Hazardous Waste Register. Every company that produces hazardous waste shall keep a Register in such
conditions as the prevailing legislation provides.
Storage of Hazardous Waste. Waste liquids shall be stored in individual and separate tanks or containers, by
type of waste. Those containers, properly closed and tagged, shall be stored in a sheltered area, on an
impermeable surface. Applicable legislation defines the storage conditions.
Transport and disposal. Before forwarding hazardous waste products resulting from the decontamination
process to the authorised waste manager, it is necessary to verify that the selected carriers can take charge of
waste transport to the manager’s premises, being duly authorised to do so and that the waste manager has the
necessary permits to process the specific waste products to be disposed of.
O&M_2.002211.810_A_10_2016
5/5
Page 36
Kohler
2.002211.810_A
10-2016
OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
CHAPTER 2 – ENGINE TECHNICAL DESCRIPTION
INDEX Chapter 2
ENGINE TECHNICAL DESCRIPTION
O&M_2.002211.810_A_10_2016
IC-G-D-00-039e_F Gas engines identification plates and characteristics 2.1.1
IC-G-D-00-253e Emissions plate of Epa certified engines 2.1.9
IC-G-D-00-040e_F Gas engines general description of construction 2.1.11
IC-G-D-00-036e_G Table of technical characteristics in-line FGLD/SFGLD/SFGM/HGM engines 2.1.15
IC-G-D-00-151e Description of the components in one circuit “V” gas engines 2.1.17
IM-G-C-00-002e_F Gaps and wear limits for “V” Gas and Ethanol engines 2.1.25
IM-G-C-00-001e_F Tightening torques for Gas and Ethanol engines 2.1.33
IM-C-C-00-002e_B Tightening torques for commercial bolts & nuts 2.1.37
IC-C-D-00-025e Units conversión 2.1.41
IT-G-A-20-025e One circuit cooling system for gas V - engines 2.2.1
IT-G-A-20-007e_I Gas engines – pressure losses and flowrates 2.2.9
IC-C-D-25-005e_C Description of lubrication system for “V” engines 2.3.1
IT-C-A-25-002e_F Automatic engine oil level controller 2.3.7
IT-C-A-25-045e_B Lube oil level indicator UL 2.3.11
IT-C-A-25-030e_G Kohler engines submerged oil preheating system 2.3.15
IC-C-D-25-006e_B Description of a crankcase Gas recirculation system 2.3.19
2.1 General
2.2 Cooling System
2.3 Lubrication System
2.4 Fuel System
IC-G-D-50-003e EGS 02. Description 2.4.1
IT-G-E-30-001e_B Venturi type carburation - description 2.4.5
IC-G-D-30-040e_A
IC-G-D-33-002e_A Description of the GIS ignition system 2.5.1
IC-C-D-35-002e_C GAS engines intake system 2.6.1
IC-C-D-35-001e_D Air filters 2.6.5
Specification of Gas supply to tecjet 52 2.4.11
2.5 Ignition
2.6 Intake
1/2
Page 37
2.002211.810_A
10-2016
ENGINE TECHNICAL DESCRIPTION
INDEX Chapter 2
OPERATION & MAINTENANCE MANUAL SFGLD “V”
KOHLER CO – PRIME / STAND BY
2.7 Exhaust
IC-C-D-40-003e_A Oxidative catalytic converters 2.7.1
IC-G-D-40-002e_B Exhaust system and ventilation of the oil sump 2.7.7
O&M_2.002211.810_A_10_2016
IT-C-A-55-001e_J Electric starting 2.8.1
IO-G-M-60-002e_K FG/FGLD/SFGLD/SFGM/SFGRD engines instrumentation 2.9.1
2.8 Starter
2.9 Safety and Control
2/2
Page 38
PRODUCT INFORMATION
2.1.1
IC-G-D-00-039e F
INDEX
DATE
January 2015
Dep.1
GAS ENGINES
IDENTIFICATION PLATES AND CHARACTERISTICS
O&M_2.002211.810_A_10_2016
1. ENGINE IDENTIFICATION PLATE
The identification plate provides engine reference information which includes:
- Engine Model.
- The power and rating of the engine.
- Serial number and manufacturing date.
On the 180/240 in-line engines it is located on the right-hand side of the crankcase (See Fig. 2); on the 360/480
and SFGLD/SFGM 560 V engines, the plate is on the front right-hand side of the crankcase (See Fig. 3), and on
the HGM 420/560 on the bottom right front panel of the water distribution box (See Fig. 4).
NOTE
When asking Kohler A Siemens Businessfor information and spare parts, please state the engine
model and serial number.
Fig. 1 – KOHLER Gas Engine Identification Plate
1/8
Page 39
2.1.2
Fig. 2 – Identification Plate Location on 180/240 Series Engines
PRODUCT INFORMATION
IC-G-D-00-039e F
INDEX
DATE
January 2015
GAS ENGINES
IDENTIFICATION PLATES AND CHARACTERISTICS
O&M_2.002211.810_A_10_2016
Dep.1
2/8
Page 40
PRODUCT INFORMATION
2.1.3
O&M_2.002211.810_A_10_2016
IC-G-D-00-039e F
IDENTIFICATION PLATES AND CHARACTERISTICS
Fig. 3 – Identification Plate Location on 360/480/560 Series Engines
INDEX
GAS ENGINES
DATE
January 2015
Dep.1
3/8
Page 41
PRODUCT INFORMATION
2.1.4
O&M_2.002211.810_A_10_2016
IC-G-D-00-039e F
INDEX
DATE
January 2015
Dep.1
GAS ENGINES
IDENTIFICATION PLATES AND CHARACTERISTICS
Fig. 4 – Identification Plate Location on “HGM 420/560” Engines
4/8
Page 42
PRODUCT INFORMATION
2.1.5
O&M_2.002211.810_A_10_2016
IC-G-D-00-039e F
INDEX
DATE
January 2015
Dep.1
GAS ENGINES
IDENTIFICATION PLATES AND CHARACTERISTICS
2. CHARACTERISTICS PLATE
The characteristics plate provides engine operating data including: Firing order, ignition timing, valve adjustment,
auxiliary circuit temperature, type of gas to be used, and compression ratio.
Fig. 5 - Characteristics Plate “180 Series” Engines
Fig. 6 - Characteristics Plate “240 Series” Engines
5/8
Page 43
PRODUCT INFORMATION
2.1.6
O&M_2.002211.810_A_10_2016
IC-G-D-00-039e F
INDEX
DATE
January 2015
Dep.1
GAS ENGINES
IDENTIFICATION PLATES AND CHARACTERISTICS
Fig. 7 - Characteristics Plate “360/420 Series” Engines
Fig. 8 - Characteristics Plate “480/560 Series” Engines
6/8
Page 44
PRODUCT INFORMATION
2.1.7
O&M_2.002211.810_A_10_2016
IC-G-D-00-039e F
INDEX
DATE
January 2015
Dep.1
GAS ENGINES
IDENTIFICATION PLATES AND CHARACTERISTICS
Fig. 9 – Characteristics Plate Location on “180/240 Series” Engines
7/8
Page 45
PRODUCT INFORMATION
2.1.8
O&M_2.002211.810_A_10_2016
IC-G-D-00-039e F
INDEX
DATE
January 2015
Dep.1
GAS ENGINES
IDENTIFICATION PLATES AND CHARACTERISTICS
Fig. 10 – Characteristics Plate Location on “360/420/480/560 Series” Engines
8/8
Page 46
PRODUCT INFORMATION
INDEX DATE
Dep. 2
IC-G-D-00-253e
April 2016
EMISSIONS PLATE OF EPA CERTIFIED ENGINES
1/2
2.1.9
O&M_2.002211.810_A_10_2016
1. ENGINE IDENTIFICATION PLATE
The emissions plate of the engines with EPA certification under 40 CFR part 60 subpart JJJJ includes the
following information:
- ENGINE FAMILY: EPA certification code corresponding to the engine model
- ENGINE DISPLACEMENT: in litres
- MAX.RATED KW: maximum engine power (the nominal engine power except for Prime applications
where a 10% of overload is allowed, see conditions in IC-C-D-00-002e or in the engine thermal balance)
- EMISSION CONTROL SYSTEM: related to the engine configuration:
o ECM Electronic Control Module for the electronic control of the carburation
o MIX for the mixture of air and fuel by a carburetor
o TC with turbocharger
o CAC with Chargecooler.
- THIS ENGINE IS CERTIFIED TO OPERATING ON: indicates the fuel which the certification is valid for
o NG (gas natural)
- THE USEFUL LIFE: running hours/years (which occurs firts) of the engine emissions certifications
warranty.
- THIS ENGINE IS CERTIFIED TO: certified emissions values of pollutants.
- EPA certification year and manufacture year.
On the 180/240 in-line engines it is located on the right-hand side of the crankcase; on the 360/480 and
SFGLD/SFGM 560 V engines, the plate is on the front right-hand side of the crankcase, and on the HGM
420/560 on the bottom right front panel of the water distribution box.
Fig. 1 - EPA emissions Plate
Page 47
PRODUCT INFORMATION
INDEX DATE
Dep. 2
IC-G-D-00-253e
April 2016
EMISSIONS PLATE OF EPA CERTIFIED ENGINES
2/2
xGSRB18.0180
SFGLD180 continuous
xGSRB24.0240
SFGLD240 continuous, Prime
xGSRB36.0360
SFGLD360 continuous, Prime
xGSRB48.0480
SFGLD480 continuous, Prime
xGSRB56.0560
SFGLD560 continuous
xGSRB24.240E
SFGLD240 Stand-by
xGSRB36.360E
SFGLD360 Stand-by
xGSRB48.480E
SFGLD480 Stand-by
2.1.10
O&M_2.002211.810_A_10_2016
The next table shows the different engine codes (ENGINE FAMILY) the certified engines have been categorized
Table 1 - Engines Family codes
The first letter “x” of the code is related to the year of the certification (f.e. for 2016, the letter is a “G”).
Page 48
PRODUCT INFORMATION
O&M_2.002211.810_A_10_2016
IC-G-D-00-040e F
INDEX
DATE
May 2016
Dep. 2
GAS ENGINES GENERAL DESCRIPTION OF CONSTRUCTION
1. BASIC SPECIFICATIONS OF GAS ENGINES
The technical characteristics of the engines are shown in:
- IC-G-D-00-034 FG engines
- IC-G-D-00-035 FGLD, SFGLD, SFGM in line engines
- IC-G-D-00-036 FGLD, SFGLD, SFGM V engines
- IC-G-D-00-131 SFGRD in line engines
- IC-G-D-00-132 SFGRD V engines
- IC-G-D-00-149 HGM engines
These are four-stroke engines with spark ignition (Otto Cycle). The SFGM and HGM series feature Miller cycle.
They belong to different categories, as follows:
- FG engines, naturally aspirated with stoichiometric combustion (lambda=1).
- SFGRD engines supercharged by turbocharger and aftercooler with rich burn technology (Lambda<1)
and low-pressure air/gas mixture.
- FGLD/SFGLD/SFGM engines supercharged by turbocharger and aftercooler with lean burn technology
(Lambda=1.3 / 1.6) and low-pressure air/gas mixture.
- HGM engines supercharged by high-compression ratio turbocharger and intercooler, with lean burn
technology (Lambda=1.4 / 1.7) and low-pressure air/gas mixture.
Kohler engines can operate on gases with different calorific capacities (LHV), see Product Information
IC-G-D-30-001e.
2. GENERAL DESCRIPTION OF THE CONSTRUCTION OF THE ENGINE
2.1. CRANKCASE
The crankcase is manufactured from grey cast iron with a stabilising heat treatment to eliminate residual
stresses. It has a high mechanical sturdiness as befits its original design oriented towards diesel applications.
The crankcase is constructed with different side openings, which allows a high degree of accessibility to internal
engine components such as connecting rods, camshafts, etc., to facilitate engine maintenance.
2.2. SLEEVES
Sleeves are from centrifuged grey cast iron and are installed on the engine block, due to which they are
interchangeable, allowing easy maintenance.
2.3. CRANKSHAFT
The crankshaft is made from die-pressed alloy steel, which is given a general heat treatment (quenching and
tempering).
2.1.11
1/4
Page 49
PRODUCT INFORMATION
O&M_2.002211.810_A_10_2016
IC-G-D-00-040e F
INDEX
DATE
May 2016
Dep. 2
GAS ENGINES GENERAL DESCRIPTION OF CONSTRUCTION
It is of the suspended block type for which reason it is secured with nodular cast iron caps and alloy steel studs,
making the engine assembly very sturdy.
The crankshaft bearings, crankpins and radii (bends) are induction-tempered to ensure surface hardness and
better performance and longer life for the crankshaft.
The crankshaft is dynamically balanced by built-in counterweights and its ends are supported by an inertia
flywheel to ensure regular operation and a torsion vibration damper.
2.4. BEARINGS
The semi-bearings used in the connecting rod head and crankshaft are manufactured from steel and the roller
track is made from aluminium tin alloy.
2.5. CYLINDER HEADS
The cylinder heads are made from grey cast iron and are individual for each cylinder, allowing high engine
maintenance.
Apart from housing the intake and exhaust piping, they have two water chambers that are part of the engine
cooling system.
Each cylinder head comes complete with a four-valve system per cylinder (2 intake and 2 exhaust) which are
formed by valve seats, valves and valve guides, as well as springs, valve plates and half-cones. All the
components fitted into the cylinder heads allow easy replacement and maintenance.
The cylinder head also houses the spark plug sleeve that accommodates an easy-to-fit/remove firing spark plug.
2.6. CONNECTING RODS
The connecting rods are die-pressed in alloy steel and are then quenched and tempered to improve their
mechanical characteristics. They are cut obliquely and with a saw-tooth joint which guarantees an adequate
joint after assembly of crank head and cap.
2.7. PISTONS
The pistons are made from aluminium alloy. The volume for the combustion is formed by the volume between
the piston TDC and the cylinder head. The pistons include a chamber shaped on piston top
The piston is jet cooled with refrigeration oil from a specific regulated pressure gallery either at the base of the
piston or through a gallery inside the piston itself.
2.8. PISTON RINGS
A piston ring set consists of three rings:
- Compression ring, i.e. a chrome-plated rectangular ring on a piston ring carrier for engines with 152mm
cylinder dia. and a ceramic trapezoidal ring for engines with 160mm dia. pistons
- Scraper ring, and
- Oil control ring
2.1.12
2/4
Page 50
PRODUCT INFORMATION
O&M_2.002211.810_A_10_2016
IC-G-D-00-040e F
INDEX
DATE
May 2016
Dep. 2
GAS ENGINES GENERAL DESCRIPTION OF CONSTRUCTION
2.9. CAMSHAFT
The camshafts (one for in-line and two in V-engines) are made from alloy steel and induction tempered or case
hardened (HGM and SFGM).
The cams have been calculated to optimise the operation of all the engine distribution; camshaft drive is through
gear arrangement.
The cam followers are of the roller type, mounted on a rocker arm.
2.10. DISTRIBUTION
Timing gears, i.e. the drive system of such components as camshafts, regulators, oil pump and water, consist of
spur gears on in-line engines and helical gears on V-engines.
2.11. LUBRICATION
The oil pump is a gear pump type, driven by means of gears from the crankshaft. The lubrication system also
consists of interchangeable filters, thermostatic oil temperature regulation (V-engines), oil refrigeration,
regulation of the lubrication oil pressure, in addition to safety systems like centrifugal filters according to the
application concerned.
2.12. REFRIGERATION
There is two types of refrigeration:
- The engine is cooled by a double water circuit. A main circuit which cools the motor crankcase, cylinder
heads and exhaust manifold (except in the case of dry exhaust manifold) as well as the air-fuel mixture on
engines with double-stage intercooler, and an auxiliary circuit for cooling the oil and the air-fuel mixture.
There are some configurations in which the oil cooler is cooled by the main circuit in parallel with the other
parts of the engine.
- The engine is cooled by just one water circuit. In line engines the oilcooler and the mixture cooler are in
series, and both in parallel to the block, cylinder-heads and exhaust manifold. In v engines oilcooler and
mixture cooler are in parallel and both are in parallel to the block, cylinder-heads and exhaust manifold.
the mixture cooler is one stage intercooler.
Cooling circuits can include pumps that can be driven by gears from the crankshaft.
2.13. CARBURETION
The gas system consists of an air/fuel ratio adjustment system (mechanical, screw-type on
FG/FGLD/SFGLD/SFGM-series engines and electronic on SFGRD/SFGLD/SFGM and HGM series engines and
a Venturi type carburettor.
Following the specifications and general standards, a valve train is always installed before the engine to
guarantee the safety of the gas installation.
2.1.13
3/4
Page 51
PRODUCT INFORMATION
O&M_2.002211.810_A_10_2016
IC-G-D-00-040e F
INDEX
DATE
May 2016
Dep. 2
GAS ENGINES GENERAL DESCRIPTION OF CONSTRUCTION
2.14. INTAKE
All the engines are supplied with an air filter system. Once the mixture has been made, it flows through the
intake manifold immediately on a naturally aspirated engine, or after passing through the compressor and
intercooler on a supercharged engine. The intake manifolds are made from aluminium in In-line engines, from
nodular casting in V engines and are provided with a safety, explosion and pressure relief valve system.
2.15. MISCELLANEOUS
The engine incorporates a crankcase gas vent for relieving pressure due to blow-by gases.
In order to ensure performance consistent with their different applications, our engines include auxiliary prelubrication systems, oil draining, oil level control, etc.
2.1.14
4/4
Page 52
PRODUCT INFORMATION
O&M_2.002211.810_A_10_2016
KOHLER
KOHLER
IC-G-D-00-036e G
INDEX
DATE
March 2015
Dep. 2
TABLE OF TECHNICAL CHARACTERISTICS FGLD/SFGLD/SFGM
"V" GAS ENGINES
ITEM UNITS
FGLD/SFGLD/SFGM
360
FGLD/SFGLD/SFGM
480
SFGLD 560 SFGM 560
No. of cylinders 12 16
Cycle 4 strokes per cycle
Cylinder Bore x
Stroke
Total cubic
capacity
Compression ratio 11:1 / 11.6:1 – 9.2.1
Firing order
Rotation direction
viewed from
Flywheel housing /
Flywheel
Valve set
Engine weight Kg / (lb)
mm / (in) 152 x 165 / (5.98 x 6.50) 160 x 175 / (6.30 x 6.90)
3
L / (In
) 35.93 / (2193) 47.90 / (2923) 56.30 / (3436)
(A)(B)
1-8-5-10-3-7-6-11-2-
9-4-12
(C)
/ 8:1
12:1-9.2.1
1-12-4-10-2-14-6-16-8-13-5-15-7-11-3-9
Anticlockwise
SAE 00 / 18"
Intake: mm / (in)
Exhaust:mm /(in)
4115-4200 /
(9072-9259)
5360-5450 /
(11816-12015)
0.3 / (0.012)
0.8 / (0.031)
W mm / (in) 1664 / (65.51) 1664 / (65.51) 1669 / (65.71)
General
dimensions
L mm / (in) 2796 / (110.08) 3033 / (119.41) 3033 / (119.41)
H mm / (in) 2258 / (88.90) 2278 / (89.69) 2270 / (89.37)
(A)(B)
/ 8:1
(C)
5800 / (12787)
12:1
COOLING SYSTEM
Types Water-water / Water-air
Main circuit
capacity
Auxiliary circuit
capacity
Standard jacket
water temperature
High jacket water
temperature
Auxiliary water
temperature
L / (gal) 180 / (47.6) 200 / (52.8)
L / (gal) 40 / ( 10.6) 50 / (13.2) 60 / (15.8)
ºC / (°F) min-std 75-90 / (167-194) // 105-120
ºC / (°F) max 96 / (205) // 125
ºC / °F
/55 /(131)
(D)
/(176)
/80
(D)
/ (221-248) 75-90 / (167-194)
(D)
/ (257) 96 / (205)
LUBRICATION SYSTEM
Natural gas KOHLER MOTOROIL 3040 Plus See IC-G-D-25-003
Type of oil
Normal oil
pressure
Oil temperature
(min/max.)
Oil capacity (max.) L / (gal)
Biogas / Syngas
Propane
(B)
MOTOROIL 99.27.046
See IC-G-D-25-004
MOTOROIL 2040 See IC-G-D-25-002
Bar / (psi) 4 – 6 / (58-87)
ºC / °F 80 – 95 / (176-203) // 80-100 / (176-212)
174 / (46.0) 233 / (61.5) 272 / (71.9)
/32 /(90)
/55 /(131)
----------------------
(E)
2.1.15
1/2
Page 53
PRODUCT INFORMATION
O&M_2.002211.810_A_10_2016
IC-G-D-00-036e G
INDEX
DATE
March 2015
Dep. 2
TABLE OF TECHNICAL CHARACTERISTICS FGLD/SFGLD/SFGM
"V" GAS ENGINES
Approximate oil
consumption
gr/kWh /
(gr/hphr)
0.35 / (0.26) 0.20 / (0.15) 0.10 / (0.07)
COMBUSTION SYSTEM
Type of
combustion
Regulation
Fuel gases
Gas regulation
valve
(A)
SFGLD Syngas and low methane number (45<NM<65) engines
(B)
SFGM propane engines
(C)
SFGLD engines with mechanical drive applications and low methane number gases (35<NM)
(D)
Natural Gas Only
(E)
SFGLD emergency engines
Lean burn (Lambda = 1.3 / 1.7)
FGLD: Fuel ratio regulation by adjusting screw (manual-mechanical carburetion)
SFGLD/SFGM: Electronic ratio regulation and also manual regulation by adjusting
screw
Natural gas / Digester / Landfill /
Well gases
(A)(C)
/ Syngas
(A)
/ Propane
(B)
Dungs (zero pressure) in mechanical carburetion
Natural gas /
Digester / Landfill
2.1.16
2/2
Page 54
PRODUCT INFORMATION
2.1.17
O&M_2.002211.810_A_10_2016
IC-G-D-00-151e
INDEX
February 2015
DATE
Dep. 8
DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS
ENGINES
Fig. 1 – Right side view
1/7
Page 55
PRODUCT INFORMATION
2.1.18
O&M_2.002211.810_A_10_2016
IC-G-D-00-151e
INDEX
February 2015
DATE
Dep. 8
DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS
ENGINES
Fig. 2 – Left side view
2/7
Page 56
PRODUCT INFORMATION
2.1.19
O&M_2.002211.810_A_10_2016
IC-G-D-00-151e
INDEX
February 2015
DATE
Dep. 8
DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS
ENGINES
Fig. 3 – Top view
3/7
Page 57
PRODUCT INFORMATION
2.1.20
O&M_2.002211.810_A_10_2016
IC-G-D-00-151e
INDEX
February 2015
DATE
Dep. 8
DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS
ENGINES
Fig. 4 – Front view
4/7
Page 58
PRODUCT INFORMATION
2.1.21
O&M_2.002211.810_A_10_2016
IC-G-D-00-151e
INDEX
February 2015
DATE
Dep. 8
DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS
ENGINES
Fig. 5 – Rear view
5/7
Page 59
PRODUCT INFORMATION
2.1.22
O&M_2.002211.810_A_10_2016
IC-G-D-00-151e
DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS
1 Crankcase
2 Connecting rod inspection door
3 Rocker arm inspection doors
4 Oil pan
5 Flywheel housing
6 Front gear cover
7 Cylinder head
8 Rocker arm cover
9 Filter Crankase gas recirculation
10 Flywheel
11 Vibration damper
12 Water circuit drainage
13 Starter
14 Jacket water thermostatic valve
15 Engine supports
16 Jacket water inlet
17 Jacket water outlet
18 Lifting eye
19 Exhaust gas outlet elbow
20 Oil cooler
21 Oil filters
22 Dipstick
23 Oil regulation and thermostat
24 Oil distributor
25 Oil centrifugal filter
26 Oil drain plug
27 Fuel gas inlet
28 Fuel gas regulator (tecjet)
29 Carburetor
30 Electronic ignition module
31 Ignition coil
32 Intake manifold
33 Throttle valve body
34 Throttle valve elbow
35 Throttle valve and intake manifold elbow union
36 Right intake manifold elbow
37 Left intake manifold elbow
38 Air filter
39 Exhaust manifolds
40 Intercooler
INDEX
ENGINES
February 2015
DATE
Dep. 8
6/7
Page 60
2.1.23
O&M_2.002211.810_A_10_2016
41 Turbocharger
42 Air cooler drain
43 Water circuit drain
44 Lubrication pump
45 Wiring Box 220V
46 Wiring Box 24V
47 Oil filling plug
48 Battery charge
49 Water preheating
PRODUCT INFORMATION
IC-G-D-00-151e
INDEX
February 2015
DATE
Dep. 8
DESCRIPTION OF THE COMPONENTS IN ONE CIRCUIT “V” GAS
ENGINES
7/7
Page 61
PRODUCT INFORMATION
2.1.25
IM-G-C-00-002e F
INDEX
January 2015
DATE
Dep. 2
GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL
ENGINES
REFERENCE GAPS & LIMITS (mm)
ITEM
DISTRIBUTION
Camshaft bushing Ø
Longitudinal gap on camshaft (locked pinion) 0.15 to 0.20 0.3
OIL CIRCUIT
Axial clearance of internal pump gears 0.100 to 0.237
Radial clearance of internal pump gears 0.075 to 0.155
Gap between gear tooth faces 0.3 to 0.5
Diametral clearance of drive shaft in pump cover and sleeve 0.075 to 0.130
Oil pump safety valve rating 8 bar
Lube oil pressure control valve rating 4.5 bar
Piston coolant pressure control valve rating 3 bar
Relief valve rating because of filter obstruction 6 bar
VALVE LIFTER
Lifter guide housing inside Ø 14.050 to 14.077
Clearance between housing and lifter 0.006 to 0.044
Lifter guide Ø 14.033 to 14.044
Clearance between lifter and rocker arm (intake) 0.3
Clearance between lifter and rocker arm (exhaust) 0.8
CYLINDER
Liner inside Ø (top) 152.000 to 152.025 152.4
Maximum out-of-roundness 0.025 0.2
Upper Ø of bore (liner housing 175.50 to 175.54
Lower Ø of bore (liner housing) 172.00 to 172.04
Protrusion of liner over cylinder block 0.04 to 0.10
CONNECTING ROD
FGLD/SFGLD/SFGM/SFE
360 480
Central / Front / Rear
O&M_2.002211.810_A_10_2016
Normal Limit
Central / Front / Rear
+0
+0,057 / 92 +0 +0,057 /
92
92
+0,110
+0,020
Width of connecting rod big end
(Pistón LCR)
Clearance between piston pin and connecting rod bearing insert
(Pistón LCR)
52.82 to 52.78
0.035 to 0.086
(0.050 a 0.102)
Diametral crankpin-to-bearing clearance 0.077 to 0.144
PISTON-RINGS
Height of piston groove 1 (compression ring) 3.56 to 3.54 3.7
Height of piston groove 2 (scraper ring) 3.56 to 3.54 3.7
Height of piston groove 3 (oil control ring) 4.04 to 4.02 4.15
Height of compression ring 1 3.475 to 3.490 3.4
Height of scraper ring 2 3.478 to 3.490 3.4
Height of oil control ring 3 3.978 to 3.990 3.9
Protrusion of the piston over the liner (dwell) -1.0 to -1.8
1/7
Page 62
PRODUCT INFORMATION
2.1.26
IM-G-C-00-002e F
INDEX
January 2015
DATE
Dep. 2
GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL
ENGINES
REFERENCE GAPS & LIMITS (mm.)
ITEM
Clearance of ring 1 in groove 1 0.05 to 0.085 0.15
Clearance of ring 2 in groove 2 0.05 to 0.082 0.15
Clearance of ring 3 in groove 3 0.03 to 0.062 0.15
End-to-end clearance of compression ring (1) 0.50 to 0.75 1.7
End-to-end clearance of scraper ring (2) 0.60 to 0.85 1.7
End-to-end clearance of oil control ring (3) 0.50 to 0.80 1.7
CRANKSHAFT
Crankpin Ø
Crankpin Ø 1st repair size 114.491 to 114.513 114.4
Crankpin Ø 2nd repair size 113.991 to 114.013 113.9
Crankshaft journal Ø 159.96 to 160.00 159.8 4
Crankshaft journal Ø 1st crankshaft repair size 159.46 to 159.50 159.3 4
Crankshaft journal Ø 2nd crankshaft repair size 158.96 to 159.00 158.8 4
Diametral gap between journal and bearing 0.120 to 0.204
Axial thrust disk thickness 5.05 to 5.11 4.85
End play of crankshaft 0.34 to 0.586 0.8
VALVE
Head angle, intake / exhaust valves
Milling angle, intake / exhaust valve seats
Free length of external spring 67.1 65
Free length of internal spring 56.6 55
Clearance of valve stem in removable guide – (LF) 0,055 a 0,08 0.15
FGLD/SFGLD/SFGM/SFE
360 480
O&M_2.002211.810_A_10_2016
Normal Limit
114.991 to 115.013 114.9
141º 0º15’
140º 0º15’
Clearance of valve stem in removable guide 0,055 a 0,08 0.15
Depression of valve with regard to cylinder head plane 1.15 to 1.50 1.75
ROCKER ARM
Rocker arm shaft 31.975 to 31.991 31.9
Clearance of rocker arm shaft in removable bushing 0.018 to 0.059 0.10
2/7
Page 63
PRODUCT INFORMATION
2.1.27
IM-G-C-00-002e F
INDEX
January 2015
DATE
Dep. 2
GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL
ENGINES
ITEM
DISTRIBUTION
Camshaft bushing Ø
Longitudinal gap on camshaft (locked pinion) 0.15 to 0.20 0.3
OIL CIRCUIT
Axial clearance of internal pump gears 0.100 to 0.237
Radial clearance of internal pump gears 0.075 to 0.155
Gap between gear tooth faces 0.3 to 0.5
Diametral clearance of drive shaft in pump cover and sleeve 0.075 to 0.130
Oil pump safety valve rating 8 bar
Lube oil pressure control valve rating 4.5 bar
Piston coolant pressure control valve rating 3 bar
Relief valve rating because of filter obstruction 6 bar
VALVE LIFTER
Lifter guide housing inside Ø 14.050 to 14.077
Clearance between housing and lifter 0.006 to 0.044
Lifter guide Ø 14.033 to 14.044
Clearance between lifter and rocker arm (intake) 0.3
Clearance between lifter and rocker arm (exhaust) 0.8 (SFGLD) / 0.5 (SFGM)
CYLINDER
Liner inside Ø (top) 160.000 to 160.025 160.4
Maximum out-of-roundness 0.025 0.2
Upper Ø of bore (liner housing 181.50 to 181.54
Lower Ø of bore (liner housing) 180.00 to 180.04
Protrusion of liner over cylinder block 0.08 to 0.14
CONNECTING ROD
Width of connecting rod big end 52.82 to 52.78
Clearance between piston pin and connecting rod bearing insert 0.050 to 0.102
Diametral crankpin-to-bearing clearance 0.077 to 0.144
PISTON-RINGS
Height of piston groove 1 (compression ring)
Height of piston groove 2 (scraper ring) 3.56 to 3.54 3.7
Height of piston groove 3 (oil control ring) 4.04 to 4.02 4.15
Height of compression ring 1
Height of scraper ring 2 3.475 to 3.490 3.4
Height of oil control ring 3 3.975 to 3.990 3.9
Protrusion of the piston over the liner (dwell) -1.0 to -1.8
REFERENCE GAPS & LIMITS (mm)
SFGLD/SFGM 560 Normal Limit
Central / Front / Rear
92+0+0.057 /92 +0 +0.057 / 92
O&M_2.002211.810_A_10_2016
Central / Front / Rear
+0.110
+0.020
3/7
Page 64
PRODUCT INFORMATION
2.1.28
IM-G-C-00-002e F
INDEX
January 2015
DATE
Dep. 2
GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL
ENGINES
O&M_2.002211.810_A_10_2016
ITEM
Clearance of ring 1 in groove 1 -
Clearance of ring 2 in groove 2 0.05 to 0.085 0.15
Clearance of ring 3 in groove 3 0.03 to 0.065 0.15
End-to-end clearance of compression ring (1) 0.40 to 0.65 1.6
End-to-end clearance of scraper ring (2) 0.80 to 1.05 1.9
End-to-end clearance of oil control ring (3) 0.50 to 0.80 1.7
CRANKSHAFT
Crankpin Ø
Crankpin Ø 1st repair size 114.491 to 114.513 114.4
Crankpin Ø 2nd repair size 113.991 to 114.013 113.9
Crankshaft journal Ø 159.975 to 160.000 159.8 4
Crankshaft journal Ø 1st crankshaft repair size 159.475 to 159.500 159.3 4
Crankshaft journal Ø 2nd crankshaft repair size 158.975 to 159.000 158.8 4
Diametral gap between journal and bearing 0.120 to 0.204
Axial thrust disk thickness 5.05 to 5.11 4.85
End play of crankshaft 0.34 to 0.586 0.8
VALVE
Head angle, intake / exhaust valves
Milling angle, intake / exhaust valve seats
Free length of external spring 67.1 65
Free length of internal spring 56.6 55
REFERENCE GAPS & LIMITS (mm.)
SFGLD/SFGM 560 Normal Limit
114.991 to 115.013 114.9
141º 0º15’
140º 0º15’
Clearance of valve stem in removable guide – (LF) 0,055 a 0,08 0.15
Clearance of valve stem in removable guide 0,055 a 0,08 0.15
Depression of valve with regard to cylinder head plane 1.15 to 1.50 1.75
ROCKER ARM
Rocker arm shaft 31.975 to 31.991 31.9
Clearance of rocker arm shaft in removable
bushing
0.018 to 0.059 0.10
4/7
Page 65
PRODUCT INFORMATION
2.1.29
IM-G-C-00-002e F
INDEX
January 2015
DATE
Dep. 2
GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL
ENGINES
O&M_2.002211.810_A_10_2016
ITEM
DISTRIBUTION
Camshaft bushing Ø
Longitudinal gap on camshaft (locked pinion) 0.15 to 0.20 0.3
OIL CIRCUIT
Axial clearance of internal pump gears 0.100 to 0.237
Radial clearance of internal pump gears 0.075 to 0.155
Gap between gear tooth faces 0.3 to 0.5
Diametral clearance of drive shaft in pump cover and sleeve 0.075 to 0.130
Oil pump safety valve rating 8 bar
Lube oil pressure control valve rating 4.5 bar
Piston coolant pressure control valve rating 3 bar
Relief valve rating because of filter obstruction 6 bar
VALVE LIFTER
Lifter guide housing inside Ø 14.050 to 14.077
Clearance between housing and lifter 0.006 to 0.044
Lifter guide Ø 14.033 to 14.044
Clearance between lifter and rocker arm (intake) 0.3
Clearance between lifter and rocker arm (exhaust) 0.5
CYLINDER
Liner inside Ø (top) 160.000 to 160.025 160.4
Maximum out-of-roundness 0.025 0.2
Upper Ø of bore (liner housing) 181.50 to 181.54
Lower Ø of bore (liner housing) 180.00 to 180.04
Protrusion of liner over cylinder block 0.08 to 0.14
CONNECTING ROD
Width of connecting rod big end 52.82 to 52.78
Clearance between piston pin and connecting rod bearing insert 0.050 to 0.102
Diametral crankpin-to-bearing clearance 0.077 to 0.144
PISTON-RINGS
Height of piston groove 1 (compression ring)
Height of piston groove 2 (scraper ring) 3.57 to 3.55 3.7
Height of piston groove 3 (oil control ring) 4.05 to 4.02 4.15
Height of compression ring 1
Height of scraper ring 2 3.475 to 3.490 3.4
Height of oil control ring 3 3.975 to 3.990 3.9
Protrusion of the piston over the liner (dwell) -1.0 to -1.8
REFERENCE GAPS & LIMITS (mm)
HGM 420 / 560 Normal Limit
Central / Front / Rear
Central / Front / Rear
92+0+0.057 /92 +0 +0.057 / 92
+0.110
+0.020
5/7
Page 66
PRODUCT INFORMATION
2.1.30
IM-G-C-00-002e F
INDEX
January 2015
DATE
Dep. 2
GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL
ENGINES
O&M_2.002211.810_A_10_2016
ITEM
Clearance of ring 1 in groove 1 -
Clearance of ring 2 in groove 2 0.060 to 0.095 0.15
Clearance of ring 3 in groove 3 0.030 to 0.075 0.15
End-to-end clearance of compression ring (1) 0.400 to 0.650 1.6
End-to-end clearance of scraper ring (2) 0.800 to 1.050 1.9
End-to-end clearance of oil control ring (3) 0.500 to 0.800 1.7
CRANKSHAFT
Crankpin Ø
Crankpin Ø 1st repair size 114.491 to 114.513 114.4
Crankpin Ø 2nd repair size 113.991 to 114.013 113.9
Crankshaft journal Ø 159.975 to 160.000 159.8 4
Crankshaft journal Ø 1st crankshaft repair size 159.475 to 159.500 159.3 4
Crankshaft journal Ø 2nd crankshaft repair size 158.975 to 159.000 158.8 4
Diametral gap between journal and bearing 0.120 to 0.204
Axial thrust disk thickness 5.05 to 5.11 4.85
End play of crankshaft 0.280 to 0.586 0.8
VALVE
Head angle, intake / exhaust valves
Milling angle, intake / exhaust valve seats
Free length of external spring
Free length of internal spring
Clearance of valve stem in removable guide (Exhaust)
Clearance of valve stem in removable guide (Intake)
Head angle, intake / exhaust valves 0.055 to 0.080 0.15
Milling angle, intake / exhaust valve seats 0.070 to 0.095 0.15
Depression of valve with regard to cylinder head plane 1.14 to 1.22 1.75
ROCKER ARM
Rocker arm shaft 31.975 to 31.991 31.9
Clearance of rocker arm shaft in removable bushing 0.018 to 0.050 0.10
REFERENCE GAPS & LIMITS (mm)
HGM 420 / 560 Normal Limit
114.991 to 115.013 114.9
141º 0º15’
121º 0º15’
140º 0º15’
120º 0º15’
69 1.69
69 1.33
67
67.5
6/7
Page 67
PRODUCT INFORMATION
2.1.31
IM-G-C-00-002e F
INDEX
January 2015
DATE
Dep. 2
GAPS AND WEAR LIMITS FOR “V” GAS AND ETHANOL
ENGINES
Other considerations for taking into account with all the engines:
The connecting rods and their bearing caps are marked with matching identification numbers in addition to the
relevant cylinder number for assembly purposes.
It is necessary to replace the connecting rod bolts either after their third retightening or according to the relevant
maintenance instructions.
The counterweight bolts must be changed at each regrinding of the crankshaft.
The lips of the front and rear seals must be oriented towards the inside of the engine and impregnated with motor
oil on assembly.
The damper is a precision device, the internal parts of which are adjusted to very close tolerances. Any wear of its
external housing can reduce its performance and cause serious damage to the engine crankshaft. It should be
changed, following the relevant instructions for that purpose.
Main bearing caps are marked with figures in ascending order from the flywheel side. These figures are
reproduced on the lower face of the cylinder block.
O&M_2.002211.810_A_10_2016
7/7
Page 68
PRODUCT INFORMATION
2.1.33
16 157
10 98
10 98
IM-G-C-00-001e F
INDEX
January 2015
DATE
Dep. 1
TIGHTENING TORQUES FOR GAS AND ETHANOL ENGINES
O&M_2.002211.810_A_10_2016
In line 180/240
ITEM REFERENCE
ENGINE BLOCK
Bearing capscrew (See IM-C-C-10-001e) 82* 804*
Bearing cap cross bolt (See IM-C-C-10-001e) 13* 128*
Cylinder head stud to crankcase (with Loctite 511) 5 49
MOVING PARTS
Counterweight to crankshaft capscrew 28.5* 280*
Connecting rod capscrew (See IM-C-C-15-002e) 50* 491*
Flywheel mounting capscrew (with Loctite 243) 36 353
Screws crankshaft companion flange front (with Loctite
243)
Vibration damper capscrew 14 137
CYLINDER HEAD
Cylinder head nut (See IM-C-C-10-002e) 48* 471*
Spark plug sleeve 23 226
Rocker arm adjusting screw 10 98
Valve lifter adjusting screw 4.5 44
SPARK PLUG (See IO-G-M-33-001, IO-G-M-33-004, IO-G-M-33-007)
DISTRIBUTION
16 157
TIGHTENING TORQUE
Kgm. Nm.
Oil pump gear fixing nut (with Loctite 243) 30 294
OTHERS
Nut for water pump impeller, main circuit
(with Loctite 243)
Water pump gear drive and bearing capscrew, main circuit
(with Loctite 243)
Engine to skid / subbase capscrew (M.20) -- 33 324
Exhaust manifold to cylinder head capscrew
Turbocharger to manifold nut 4,5 / 4,5 44 / 44
10 98
Wet / Dry
8.3 / 4,5 81 / 44
6 / 4,5 59 / 44
NOTE
* Oil lubricated (with plenty of motor oil)
General directive for tightening torques based on screw quality and diameter.
These values should be used unless expressly specified otherwise. See IM-C-C-00-002e.
1/3
Page 69
PRODUCT INFORMATION
2.1.34
10 98
18 177
IM-G-C-00-001e F
INDEX
January 2015
DATE
Dep. 1
TIGHTENING TORQUES FOR GAS AND ETHANOL ENGINES
O&M_2.002211.810_A_10_2016
FGLD/SFGLD/SFGM 360/480/560
ITEM REFERENCE
ENGINE BLOCK
Bearing cap fixing stud 10* 98*
Bearing cap nut (See IM-C-C-10-001e) 102* 1001*
Bearing cap cross bolt (See IM-C-C-10-001e) 28* 275*
Cylinder head stud to crankcase (with Loctite 511) 5 49
Cyl. head stud SFGLD 560 (with Loctite 511) 5 49
MOVING PARTS
Counterweight to crankshaft capscrew 28,5* 280*
Vibration damper capscrew 14 137
Connecting rod capscrew (See IM-C-C-15-002e) 50* 491*
Crankshaft rear output flange capscrew (flywheel) 43* 421*
Flywheel capscrew 31* 304*
CYLINDER HEAD
Cylinder head nut (See IM-C-C-10-002e) 48* 471*
Cyl. head nut SFGLD/SFGM 560 (See IM-C-C-10-002e)
Spark plug sleeve / SFGM560 23 226
Rocker arm adjusting screw 10 98
Valve lifter adjusting nut 4,5 44
SPARK PLUG (See IO-G-M-33-001, IO-G-M-33-004, IO-G-M-33-007)
DISTRIBUTION
45* 441*
TIGHTENING TORQUE
Kgm. Nm.
Oil pump gear fixing nut (with Loctite 243) 35 343
OTHERS
Nut for water pump impeller, main & auxiliary circuits
(with Loctite 243)
Water pump gear drive and bearing capscrew, main &
auxiliary circuits (with Loctite 243)
Engine to skid / subbase capscrew (M.20) -- 33 324
Exhaust manifold to cylinder head capscrew
Turbocharger to manifold capscrew 4,5 / 4,5 44 / 44
10 98
18 177
Wet / Dry
8,3 / 4,5 81 / 44
6,5 / 4,5 64 / 44
NOTE
* Oil lubricated (with plenty of motor oil)
General directive for tightening torques based on screw quality and diameter.
These values should be used unless expressly specified otherwise. See IM-C-C-00-002e.
2/3
Page 70
PRODUCT INFORMATION
2.1.35
10 98
18 177
IM-G-C-00-001e F
INDEX
January 2015
DATE
Dep. 1
TIGHTENING TORQUES FOR GAS AND ETHANOL ENGINES
O&M_2.002211.810_A_10_2016
HGM 420 / 560
ITEM REFERENCE
ENGINE BLOCK
Bearing cap fixing stud 10* 98*
Bearing cap nut (See IM-C-C-10-001e) 102* 1001*
Bearing cap cross bolt (See IM-C-C-10-001e) 28* 275*
Cylinder head stud to crankcase (with Loctite 511) 5 49
MOVING PARTS
Counterweight to crankshaft capscrew 28,5* 280*
Vibration damper capscrew 14 137
Connecting rod capscrew (See IM-C-C-15-002e) 50* 491*
Crankshaft rear output flange capscrew (flywheel) 43* 421*
Flywheel capscrew 31* 304*
CYLINDER HEAD
Cylinder head nut 48* 441*
Spark plug sleeve 23 226
Rocker arm adjusting screw 10 98
Valve lifter adjusting screw 4,5 44
SPARK PLUG (See IO-G-M-33-001, IO-G-M-33-004, IO-G-M-33-007)
DISTRIBUTION
TIGHTENING TORQUE
Kgm. Nm.
Oil pump gear fixing nut (with Loctite 243) 35 343
OTHERS
Nut for water pump impeller, main & auxiliary circuits (with
Loctite 243)
Water pump gear drive and bearing capscrew, main &
auxiliary circuits (with Loctite 243)
Engine to skid / subbase capscrew (M.20) -- 33 324
Exhaust manifold to cylinder head capscrew 4,5 44
Turbocharger to manifold nut 4,5 44
10 98
18 177
NOTE
* Oil lubricated (with plenty of motor oil)
General directive for tightening torques based on screw quality and diameter.
These values should be used unless expressly specified otherwise. See IM-C-C-00-002e.
3/3
Page 71
PRODUCT INFORMATION
2.1.37
IM-C-C-00-002e B
INDEX
DATE
February 2012
Dep.2
TIGHTENING TORQUES FOR COMMERCIAL BOLTS & NUTS
O&M_2.002211.810_A_10_2016
1. STANDARD TIGHTENING TORQUE SPECIFICATION
Tabulated below are the tightening torques for commercial bolts and nuts according to their metric threads and
grades.
GRADE
THREAD
8.8 10.9 12.9
N.m Ft.lb N.m Ft.lb N.m Ft.lb
M.5
M.6
M.8
M.10
M.12
M.14
M.16
M.18
M.20
M.22
M.24
M.27
M.33
6 4.4 9 6,6 11 8.1
11 8 15 11 18 13.3
25 18 34 25 43 32
47 35 65 48 83 61
78 58 113 83 140 103
120 86 175 129 210 155
180 133 260 192 310 229
250 184 360 266 430 317
330 243 470 347 560 413
430 317 600 443 720 531
560 413 790 583 950 701
710 524 1060 782 1180 870
1110 819 1540 1136 1730 1276
Table 1 – Tightening torques for the fasteners’ different threads and grades
Screw tightening torques outside this standard specification are listed in documents IM-F-C-00-002e and IM-F-C00-004e for diesel and dual-fuel engines and IM-G-C-00-001e for gas and ethanol engines.
2. CALCULATING THE SCREW PRE-STRESSING FORCE ACCORDING TO THE
APPLIED TIGHTENING TORQUE
The screw tightening torque is useful for two purposes:
- To overcome friction between contact areas, whether between screw and nut threads or between screw head
and bearing surface.
- To apply a pre-stressing force to the fastener.
The amount of tightening torque usable for applying the pre-stressing force varies depending on the coefficient of
friction to overcome. Therefore, even though the same tightening torque is applied to two identical screws, the
pre-stressing force can vary if the coefficient of friction is different in both instances. The lower the coefficient, the
lower the effort needed to overcome friction and consequently, the pre-stressing force will be greater.
Torques table 1 has been calculated with a coefficient of friction standard for steel μ=0.14. For other coatings,
look at Table 2.
1/3
Page 72
PRODUCT INFORMATION INDEX DATE
2.1.38
IM-C-C-00-002e B
February 2012
Dep.2
TIGHTENING TORQUES FOR COMMERCIAL BOLTS & NUTS
O&M_2.002211.810_A_10_2016
Coating
Steel with cadmium 0.07 0.07
Cadmium with zinc 0.1 0.08
Cadmium with cadmium 0.1 0.07
Steel with phosphate 0.11 0.1
Phosphate with cadmium 0.11 0.08
Phosphate with zinc 0.11 0.11
Phosphate with phosphate 0.12 0.1
Steel with zinc 0.14 0.07
Table 2 – Co
In any case, the normal coefficient of friction used is 0.14 for clean and non-lubricated steel-to-steel assembly. If
the screw and the mating threads are of steel, clean and lubricated, this coefficient is 0.1.
From a known coefficient of friction, it is possible to calculate the pre-stressing force using this formula.
dnS
([ pdf
PM
v
efficient of friction for different coatings
]16.0)58.0
4
Normal Lubricated
df
S
dn
p
v
diameterside
1
2
Coefficient of friction
diameter Washer´s
diameter nominal Screw
pitch Screw
:offriction of coeficient average The
part and screwbetween friction of Coeficient
threadpart´s and screwin friction of Coeficient
MP
torque with theobtainedforce stressing-Pre
To determine whether a screw will resist a pre-stressing force (as calculated from a known tightening torque and
coefficient of friction), it is necessary to know the mechanical properties of that screw. The following table shows
those properties.
GRADE
2
Tensile strength (N/mm
Yield strength (N/mm2) 627 882 1058
Extension to the breakage (%) min 12 9 8
Resilience (N.m/cm2) 59 39 29,4
Hardness HRC
Table 3 – Mechanical properties of screws used
)
Min. 784
Max. 980 1176 1372
Min. 18
Max. 31 38 44
(acc. to DIN 267)
8.8 10.9 12.9
980 1176
27 34
2/3
Page 73
PRODUCT INFORMATION
2.1.39
IM-C-C-00-002e B
INDEX
DATE
February 2012
Dep.2
TIGHTENING TORQUES FOR COMMERCIAL BOLTS & NUTS
O&M_2.002211.810_A_10_2016
3. AUXILIARY SCREW DRIVING PRODUCTS
All screwed joints must have all their parts perfectly clean and assembled applying oil to the threads. For special
applications, different products are usable for assembly. The following situations occur.
- Screws that never need to be removed, which can come loose due to vibration or for other reasons. In those
cases, high strength threadlocker (Loctite 270) will be used.
- Screws that will be removed only on rare occasions, which can come loose due to vibration or for other
reasons. In those cases, medium strength threadlocker (Loctite 243) will be used.
- Screws that never need to be removed, which fix low-pressure oil or water pipes, where gaps between threads
are small. Medium strength thread sealant (Loctite 542) will be used.
- Screws that will have to be removed, which fix low-pressure oil or water pipes, where gaps between threads
are small. They require low-strength thread sealant (Loctite 511).
- Screws that never need to be removed, which fix high-pressure oil or water pipes, where gaps between
threads are important. They require high-strength threadlocker (Loctite 270 with Activator N [7649]).
- Awkward bolts and nuts, where high tightening torque accuracy and a known steady coefficient of friction are
necessary, which will have to be removed, even after working in bad conditions. They require the application
of solid lubricants for bolted metal joints (Molykote 1000).
3/3
Page 74
PRODUCT INFORMATION
2.1.41
IC-C-D-00-025e
INDEX
December 2013
UNITS CONVERSION
DATE
Dep. 2
Length
1 inch (in)
1 foot (ft)
1 yard (yd)
Area
Volume
1 cubic.in
1 cubic ft
1 US gallon
Mass
1 pound (lb)
Torque
12 in
3 ft
1 sq.in
1 sq.ft
25.4 mm
2.54 cm
0.0254 m
304.8 mm
30.48 cm
0.3048 m
914.4 mm
91.44 cm
0.9144 m
645.16 mm
6.4516 cm
929.03 cm
0.092903 m
16.387 cm
0.016387 dm
28.317 dm
0.028317 m
3.7854 dm
0.0037854 m
453.59 g
0.45359 kg
2
2
2
2
3
(c.c)
3
(liters)
3
(liters)
3
3
(liters)
3
O&M_2.002211.810_A_10_2016
0.039370 in
1 mm
0.0032808 ft
0.0010936 yd
10 mm
1 cm
100 cm
1 m
2
1 cm
2
10000 cm
1 m
2
0.39370 in
0.032808 ft
0.010936 yd
39.370 in
3.2808 ft
1.0936 yd
0.155 sq. In
0.0010764 sq ft
1550 sq. In
10.764 sq ft
0.061024 cu.in
3
1 cm
(c.c)
0.000035315 cu.ft
0.00026417 gal
3
3
(liters)
3
1 m
(c.c)
(liters)
3
1000 cm
1 dm
1000 dm
61.024 cu.in
0.035315 cu.ft
0.26417 gal
61024 cu.in
35.315 cu.ft
264.17 gal
1 kg 2.2046 lb
1 ft lb 1.3558 N m 1 N m 0.73756 ft lb
Power
1 hp 0.7457 kW 1 W
1000 Btu/hr 0.293 kW
1 Btu/min 0.01759 kW
1000 W
1 kW
1000 kW
1 MW
0.0013410 HP
3,4121 Btu/hr
0.056838 Btu/min
1.3410 HP
3412.1 Btu/hr
56.838 Btu/min
1341.0 HP
3412100 Btu/hr
56868 Btu/min
1/2
Page 75
PRODUCT INFORMATION
2.1.42
IC-C-D-00-025e
INDEX
December 2013
UNITS CONVERSION
DATE
Dep. 2
O&M_2.002211.810_A_10_2016
Energy
1 Btu
1.0551 kJ
0.00029307 kWh
(0.00027778 KWh)
1 kJ
0.94782 Btu
Temperature
ºF = ºC x 1,8 + 32 K = ºC + 273,15
Presure
psi In HG in H2O kPa bar kg/cm2 mmH2O
1 2.0360 27.68 6.8948 0.068948 0.070307 703.07
0.49115 1 13.595 3.3864 0.033864 0.034532 345.32
0.036127 0.073556 1 0.24909 0.0024909 0.00254 25.400
0.14504 0.2953 4.0146 1 0.01 0.010197 101.97
14.504 29.53 401.46 100 1 1.0197 10197
14.223 28.959 393.70 98.067 0.98067 1 10000
0.0014223 0.0028959 0.039370 0.0098066 0.000098066 0.0001000 1
2/2
Page 76
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I
-G-A-20
MATION
025e
Dep
2
Sep
DATE
ember 201
INDEX
1 INTR
KOHLER
operation.
In order to
transfer an
In the case
are cooled
2 COOL
Below we
component
DUCTIO
engines re
cool the en
the non-ap
of gas engi
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NG CIRC
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es with sin
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GAS V-E
O&M_2.002211.810_A_10_2016
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1. Main
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7. Main
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Figure 1 V
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point of the
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point of cool
mp
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ooling circu
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and engine
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water vent
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1/
Page 77
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2.2.2
I
-G-A-20
MATION
025e
Dep
2
Sep
DATE
ember 201
INDEX
2.1 ENGIN
2.1.1 JAC
The main p
the front o
cooling eve
From the fr
that either
external co
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-MOUNTE
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ump draws
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COOLING
CIRCUIT
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cooled exh
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ING SYS
equipment
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inside the
on of the se
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GAS V-E
O&M_2.002211.810_A_10_2016
es it throug
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2
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4
5
Jacket
Water
Water
Water i
Cooled
water pump
ump inlet
upply line t
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exhaust m
Figure
engine
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Jacket Wa
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Cyli
6
The
7
Jac
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Wat
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stem. FRO
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mostatic va
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T VIEW
ve
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pipe
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2/
Page 78
C
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2.2.3
I
-G-A-20
MATION
025e
Dep
2
Sep
DATE
ember 201
INDEX
NE CIRC
Figure 3–
acket Wate
UIT COO
cooling sys
ING SYS
em. (LEFT
EM FOR
IDE VIEW)
GAS V-E
O&M_2.002211.810_A_10_2016
GINES
2.1.2 OIL
OOLER AN
INTERCO
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Fi
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and interco
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3/
Page 79
234
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2.2.4
I
-G-A-20
MATION
025e
Dep
2
Sep
DATE
ember 201
INDEX
NE CIRC
UIT COO
ING SYS
EM FOR
GAS V-E
O&M_2.002211.810_A_10_2016
GINES
1
Oilcoole
Oilcoole
Oilcoole
Intercool
inlet pipe
outlet pipe
er inlet pipe
F
igure 5 Plat
s Oilcooler
5
6
nd intercoo
I
tercooler
I
tercooler o
hermostatic
er
tlet pipe
valve
4/
Page 80
PRODUCT INFORMATION
2.2.5
IT-G-A-20-025e
INDEX
September 2014
DATE
ONE CIRCUIT COOLING SYSTEM FOR GAS V-ENGINES
Dep. 2
O&M_2.002211.810_A_10_2016
3 COOLING SYSTEM COMPONENTS
3.1 IMPELLER PUMP
Responsible for passing the right amount and pressure of cooling water past all elements of the engine. This
is a timing gear-driven centrifugal pump located on the front left side of the engine.
Figure 6 Jacket water pump
Driven gear
1
Bearing
2
Seals
3
Impeller
4
3.2 OIL COOLER
Lubrication and cooling oil cooling system.
3.3 ENGINE BLOCK
Distributes water to the engine block to cool the liners and then the cylinder heads.
3.4 AIR OR AIR/FUEL INLET COOLER
This is the component of turbocharged engines that cools the air or air/fuel inlet mixture, which is heated by
compression in the turbocharger, before it enters the combustion chamber.
5/8
Page 81
PRODUCT INFORMATION
2.2.6
IT-G-A-20-025e
INDEX
September 2014
DATE
ONE CIRCUIT COOLING SYSTEM FOR GAS V-ENGINES
Dep. 2
O&M_2.002211.810_A_10_2016
3.5 WATER PREHEATING SYSTEM
This is an auxiliary system that allows the engine cooling water to be at the optimum temperature when the
engine starts from cold. This system consists of a heating element that heats up the water and, occasionally,
an auxiliary water pump that distributes the water throughout the engine. See IT-C-A-20-009.
3.6 WATER TEMPERATURE REGULATOR
The temperature of the water in the circuit needs to be controlled in order to stay at the right temperature.
This can be done by means of thermostatic valves that are installed in a thermostat box or by electronic
regulation using 3-way valves.
Temperature regulation using thermostatic valves is generally used for cases where precise temperature
control is needed, as they control ranges from 8 to 10ºC. Electronic regulation is used for cases where
precise temperature control is needed, in heat recovery applications for example.
3.6.1 CAJA DE TERMOSTATOS CIRCUITO PRINCIPAL
The thermostat housing is located at the front of the engine and contains seven thermostatic valves whose
function is to maintain the water temperature in the engine within a range (80-90 ° C).
If the temperature is lower than the desired most of the water is directed back to the suction of the main
pump to re-enter the engine.
However a small amount of cooling water always circulates through the external thermostat housing cooling
element. This slight flow of water that is allowed to pass is used to trap air, avoiding the formation of air
pockets in the coolant circuit.
When the cooling water temperature exceeds the starting temperature of opening of the thermostat, water
flowing through the thermostatic valves and out to the external cooling system..
Figure 7– Thermostate housing.
6/8
Page 82
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2.2.7
I
-G-A-20
MATION
025e
Dep
2
Sep
DATE
ember 201
INDEX
3.7 VENT
n element
3.8 EXPAN
Due to the i
The expan
pipe mus
All venting
The expan
below a mi
steam or ai
The
1
The
2
Pur
3
that purges
SION TAN
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ipes on the
ion tank m
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mostatic Val
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expansion
circuit must
st be fitted
and a safet
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NE CIRC
ucing
ves
air pocket
ed water, a
ed at the hi
tank to the
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O&M_2.002211.810_A_10_2016
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7/
Page 83
PRODUCT INFORMATION
2.2.8
IT-G-A-20-025e
INDEX
September 2014
DATE
ONE CIRCUIT COOLING SYSTEM FOR GAS V-ENGINES
Dep. 2
O&M_2.002211.810_A_10_2016
4 REQUIREMENTS OF THE ENGINE COOLING SYSTEM
The cooling system must be able to dissipate all the heat generated by the engine and keep the same at
the correct in all possible operating conditions.
The heat generated and the cooling temperature are reflected in the thermal balances of each engine.
The heat generated by the engine and shown on the thermal balance sheet is a value determined under
specific operating parameters and standard conditions, meaning that in real conditions the heat
generated by the engine may vary, depending on its operating conditions and on environmental
conditions. The cooling circuit should be sized taking into account these variations, as well as taking into
account the fact that the cooling system may well get dirty. KOHLER recommends having a
reserve capacity of 15%.
The cooling liquid must satisfy the requirements listed in product information IO-C-M-20-001. The cooling
circuit must be designed to take into account the fact that using antifreeze in the coolant reduces heat
transfer by 3% for each 10% of antifreeze added to the coolant.
The cooling circuit pressure must always be positive throughout the circuit and comply with all minimum
requirements laid down for each engine in product information sheets IO-G-M-60- 002, IO-G-M-60-006,
IO-F-M-60-002 and IO-D-M-60-001.
The cooling circuit must have a certain flow rate, defined in product information sheets IT-G-A-20-007
and IT-F-A-20-005.
8/8
Page 84
PRODUCT INFORMATION
2.2.9
IT-G-A-20-007e I
INDEX
DATE
May 2015
Dep. 2
GAS ENGINES – PRESSURE LOSSES AND FLOWRATES
O&M_2.002211.810_A_10_2016
1. INTRODUCTION
When calculating pressure losses in the cooling circuits of gas engines. Product Information Datash eets
IT-C-A-20-001e and IT-C-A-20-002e apply. The former explains how to calculate pressure losses based on the
components layout. while the latter summarises the pressure losses for each separate component.
To define flowrates in addition to the parameters that guarantee correct performance of the engine against seizing
or knocking. we take it into account that the flowing-through velocity in the heat exchanger pipes should not be
less than 1m/s nor greater than 3m/s.
CAUTION
Maximum flowrate in the main circuit depends on the external cooling system. while the maximum flowrate in
the auxiliary circuit is determined by the passage cross section in the air and oil coolers and should not exceed
3
/h.
30m
According to the temperature of the primary and/or secondary cooling circuit(s). the minimum flowrates will vary.
WARNING
The circuit's pressure loss (Delta P) and restriction (K) are valid for a basic engine configuration with mechanical
pumps as defined in section 5 of this document. Any change to the components of said configuration will entail
recalculating both aforementioned parameters. For instance. if the engine incorporates electric pumps. the
thermostat box is different from that specified for engines with mechanical pumps; therefore. you need to
recalculate both the restriction and the pressure loss.
Considerations to take into account in other engine applications or engine configurations
The minimum flowrates specified for both cooling circuits apply to "continuous" duty equipment. For
"standby" units. the minimum flowrate shall be determined. increasing it in the same proportion as power
does in relation to the tabulated flowrates.
Minimum flowrates are the same for engines with dry exhaust manifolds and with (wet) cooled exhaust
manifold.
For variable speed engines the Minimum flows are the same that for constant speed engines
1/7
Page 85
PRODUCT INFORMATION
2.2.10
IT-G-A-20-007e I
INDEX
DATE
May 2015
Dep. 2
GAS ENGINES – PRESSURE LOSSES AND FLOWRATES
2. MINIMUM FLOWRATES FOR FGLD ENGINES
2.1 MAIN COOLING CIRCUIT
Engine
FGLD180
FG180
FGLD240
FG240
FGLD360
FGLD480
2.2 AUXILIARY COOLING CIRCUIT
Engine
Speed Temperature Minimum Flowrate Delta P
[rpm] [ºC] [m3/h] [bar]
1500
FGLD180
1800
1500
FGLD240
1800
1500
FGLD360
1800
1500
FGLD480
1800
Speed Minimum flowrate Delta P
[rpm] [m3/h] [bar]
1500 25 0.28
1800 30 0.41
1500 30 0.30
1800 35 0.40
1500 50 0.25
1800 60 0.36
1500 60 0.40
1800 70 0.54
55(Biogas)
55 0.45 2.01·10-3
80 0.46 2.04·10-3
55
80 0.82 2.04·10-3
55(Biogas)
55 (90 Main C.) 0.80 2.01·10-3
55 (120 Main C.) 0.82 2.04·10-3
80 0.7 1.76·10-3
55(Biogas)
55 1.26 2.01·10-3
80 1.10 1.76·10-3
55 (90 Main C.)
55 (120 Main C.) 0.45 1.13·10-3
80 (90 Main C.) 0.45 1.13·10-3
80 (120 Main C.) 0.46 1.16·10-3
55
80 0.71 1.13·10-3
55 (90 Main C.)
55 (120 Main C.) 0.46 1.16·10-3
80 0.47 1.18·10-3
55
80 0.74 1.18·10-3
15
20
20
25
20
25
20
25
O&M_2.002211.810_A_10_2016
K
-4
4.5·10
3.3·10
1.0·10
1.1·10
-4
-4
-4
K
0.42 1.86·10
0.81 2.01·10
0.74 1.86·10
1.16 1.86·10
0.45 1.13·10
0.68 1.09·10
0.45 1.13·10
0.71 1.13·10
-3
-3
-3
-3
-3
-3
-3
-3
2/7
Page 86
PRODUCT INFORMATION
2.2.11
IT-G-A-20-007e I
INDEX
DATE
May 2015
Dep. 2
GAS ENGINES – PRESSURE LOSSES AND FLOWRATES
3. MINIMUM FLOWRATES FOR SFGLD / SFGRD / SFGM ENGINES
3.1 MAIN COOLING CIRCUIT – TWO CIRCUITS
Engine
SFGLD/SFGRD/SFGM180
SFGLD/SFGRD/SFGM 240
SFGLD/SFGRD/SFGM 360
SFGLD/SFGRD/SFGM 480
SFGLD/SFGRD SFGM /560
3.2 MAIN COOLING CIRCUIT – ONE CIRCUIT
Speed Minimum flowrate Delta P
[rpm] [m3/h] [bar]
1200 20 0.18
1500 25 0.28
1800 30 0.41
1200 25 0.21
1500 30 0.30
1800 40 0.53
1200 40 0.16
1500 50 0.25
1800 60 0.36
1200 50 0.28
1500 60 0.40
1800 80 0.70
1200 60 0.40
1500 70 0.54
1800 75 0.62
O&M_2.002211.810_A_10_2016
K
-4
4.5·10
-4
3.3·10
-4
1.0·10
-4
1.1·10
Engine
SFGLD 180
SFGLD 240
SFGLD 360
SFGLD 480
SFGLD 560
Speed Minimum flowrate Delta P
[rpm] [m3/h] [bar]
K
1800 40 0,43 2,7·10
1800 50 0,30 1,2·10
1800 60 0,14 3,9·10
1800 80 0,25 3,9·10
1800 88 0,30 3,9·10
-4
-4
-5
-5
-5
3/7
Page 87
PRODUCT INFORMATION
2.2.12
IT-G-A-20-007e I
INDEX
DATE
May 2015
Dep. 2
GAS ENGINES – PRESSURE LOSSES AND FLOWRATES
3.3 AUXILIARY COOLING CIRCUIT. SINGLE-STAGE AIRCOOLER
Speed Temperature
Engine
[rpm] [ºC] [m3/h] [bar]
1200/1500
SFGLD/SFGRD/SFGM180
1800
55
80 0.43 1.89·10-3
55
80 0.76 1.89·10-3
1200 55 15 0.43 1.89·10
40 – 55
80 0.64 1.61·10-3
55
80 1.01 1.61·10-3
55 15 0.25 1.09·10
SFGLD/SFGRD/SFGM240
1500
1800
1200
40 – 55 (90 Main C)
1500
SFGLD360
55 (120 Main C)
80 (90 Main C)
80 (120 Main C) 0.46 1.16·10-3
55 (90 Main C)
1800
80 (90 Main C) 0.71
80 (90 Main C) 0.71
80 (120 Main C) 0.73 1.16·10-3
1200
55 15 0.25 1.13·10
40 – 55 (90 Main C)
SFGLD480
SFGLD560
1500
1800
1200
1500
55 (120 Main C) 0.46 1.16·10-3
80 0.47 1.18·10-3
55
80 0.74 1.18·10-3
55 15 0.25
32 – 55 25 0.71
Minimum
Flowrate
15
20
20
25
20
25
20
25
O&M_2.002211.810_A_10_2016
Delta P K
0.42 1.86·10
0.74 1.86·10
0.76 1.89·10
1.18 1.89·10
0.44 1.09·10-3
0.45 1.13·10
0.68 1.09·10
1.13·10
0.45 1.13·10
0.71 1.13·10
1.13·10
-3
-3
-3
-3
-3
-3
-3
-3
-3
-3
-3
-3
-3
4/7
Page 88
PRODUCT INFORMATION
2.2.13
IT-G-A-20-007e I
INDEX
DATE
May 2015
Dep. 2
GAS ENGINES – PRESSURE LOSSES AND FLOWRATES
3.4 AUXILIARY COOLING CIRCUIT. DOUBLE-STAGE AIRCOOLER
Engine
Speed Temperature
[rpm] [ºC] [m3/h] [bar]
1200 55 15 0.47
SFGLD/SFGRD/SFGM 360
1500 40 – 55 23 1.09
1800 55 25 1.29
1200 55 18 0.67
SFGLD/SFGRD/SFGM 480
1500 40 – 55 23 1.09
1800 55 25 1.29
1200 55 17 0.6
SFGLD/SFGRD/SFGM 560
1500 40 – 55 21 0.9
1800 55 25 1.28
4. MINIMUM FLOWRATES FOR HGM ENGINES
4.1 MAIN COOLING CIRCUIT
Engine Speed Minimum Flowrate
[rpm] [m3/h] [bar]
HGM240
1500 36 0,71
1800 45 1.11
HGM420
1500 55 1.27
1800 60 1.52
1200 55 0.53
HGM560
1500 70 0.87
1800 80 1.13
4.2 AUXILIARY COOLING CIRCUIT.
4.2.1 DOUBLE STAGE INTERCOOLER
Minimum
Flowrate
O&M_2.002211.810_A_10_2016
Delta P
K
2.06·10
2.06·10
Delta P
K
5,48·10
4.23· 10
1.78·10
-3
-3
-4
-4
-4
Engine Speed
[rpm] [ºC] [m3/h] [bar]
HGM420
1500
1800 25 1.18
1200 12 0.27
HGM560
1500 21 0.83
1800 25 1.18
Temperature
40-55
Minimum Flowrate
21 0.83
Delta P
K
1.90·10
-3
5/7
Page 89
PRODUCT INFORMATION
2.2.14
IT-G-A-20-007e I
INDEX
DATE
May 2015
Dep. 2
GAS ENGINES – PRESSURE LOSSES AND FLOWRATES
O&M_2.002211.810_A_10_2016
4.2.2 SINGLE STAGE INTERCOOLER
Engine
HGM240
Speed
Temperature
[rpm] [ºC] [m3/h] [bar]
1500
1800 22 0.56
55
Minimum Flowrate
20 0,46
Delta P
K
1,16·10
-3
5. BASIC CONFIGURATIONS
The following are the basic configurations used to determine the pressure losses in the main and auxiliary cooling
circuits of the above-listed engines.
5.1 MAIN COOLING CIRCUIT
Engine Cyl. Block Thermostat Box
SFGLD/SFGRD/SFGM/FGLD/FG180
SFGLD/SFGRD/SFGM/FGLD/FG240
SFGLD/SFGRD/SFGM/FGLD360
SFGLD/SFGRD/SFGM/FGLD480
SFGLD/SFGRD/SFGM560
5.2 AUXILIARY COOLING CIRCUIT. SINGLE-STAGE AIRCOOLER
Engine Oil cooler Aircooler Thermostat Box
FGLD180
FGLD180 (Landfill/Digester)
FGLD240
FGLD240 (Landfill/Digester)
FGLD360
FGLD480
YES YES YES (1 Thermostat)
YES YES YES (1 Thermostat)
YES YES YES (1 Thermostat)
YES YES YES (1 Thermostat)
YES YES YES (2 Thermostats)
YES YES YES (2 Thermostats)
Engine
SFGLD/SFGRD/SFGM180
SFGLD/SFGRD/SFGM240
SFGLD360
SFGLD480
SFGLD560
Oil cooler Aircooler Thermostat Box
YES YES YES (1 Thermostat)
YES YES YES (1 Thermostat)
YES YES YES (2 Thermostats)
YES YES YES (2 Thermostats)
YES YES YES (2 Thermostats)
5.3 AUXILIARY COOLING CIRCUIT. DOUBLE-STAGE AIRCOOLER
Engine Oil cooler Aircooler Thermostat Box
SFGLD/SFGRD/SFGM360
SFGLD/SFGRD/SFGM480
SFGLD/SFGRD/SFGM560
YES YES YES (2 Thermostats)
YES YES YES (2 Thermostats)
YES YES YES (2 Thermostats)
YES YES (3 Thermostats)
YES YES (3 Thermostats)
YES YES (7 Thermostats)
YES YES (7 Thermostats)
YES YES (7 Thermostats)
6/7
Page 90
PRODUCT INFORMATION
2.2.15
IT-G-A-20-007e I
INDEX
DATE
May 2015
Dep. 2
GAS ENGINES – PRESSURE LOSSES AND FLOWRATES
O&M_2.002211.810_A_10_2016
5.4 COOLING CIRCUIT HGM
5.4.1. Main Cooling Circuit
Motor Cyl. Block Oil cooler
HGM240
HGM420
HGM560
YES YES NO YES (4 Thermostats)
YES NO YES YES (6 Thermostats-Dist. box)
YES NO YES YES (6 Thermostats-Dist. box)
Distribution box
19.20.C60
Thermostat Box
5.4.2. Auxiliary Cooling Circuit.
Motor Oil cooler Air cooler Distribution Box Thermostat Box
HGM240
HGM420
HGM560
NO YES NO YES (2 Thermostats)
YES YES YES YES (4 Thermostats- Dist. box)
YES YES YES YES (4 Thermostats- Dist. box)
7/7
Page 91
PRODUCT INFORMATION
2.3.1
IC-C-D-25-005e C
INDEX
February 2012
DATE
Dep. 2
DESCRIPTION OF LUBRICATION SYSTEM
FOR “V” ENGINES
O&M_2.002211.810_A_10_2016
1. INTRODUCTION
The purpose of the engine lubrication system is to:
- Provide pressurised oil for hydrodynamic lubrication, minimizing friction between parts moving in relation to
each other (crankshaft, connecting rods, etc.).
- Regulate the oil pressure so as to ensure correct lubrication.
- Filter oil adequately in order to maintain its lubricating properties.
- Cool the engine.
- Protect the engine parts, like the filters, seals, etc., against oil overpressure by means of relief valves.
2. DESCRIPTION
The lubricating system comprises the following elements:
- Wet oil sump, suction tube and oil level indicator.
- Geared oil pump with overpressure safety valve.
- Lube oil pressure regulating valve.
- Oil temperature thermostatic regulation.
- Oil cooler.
- Clogged filter valve.
- Safety oil pressure switch.
- Oil filters.
- Jet pressure regulation valve.
- Centrifugal filter (diesel, biogas, low methane number gases and propane engines).
- Blow-by gas exhaust system: crankcase breathers.
2.1. OIL SUMP
An oil sump or oil tank encloses the bottom of the crankcase. The amount of oil it contains depends on the engine
model. A threaded drain plug is fitted to the lowest point in the sump.
Located in the crankcase is the oil suction tube which is fitted with a grille, preventing the suction of foreign
material into the oil circuit.
The dipstick, which allows visual control of the oil level, is also located in the sump.
2.2. OIL PUMP
This is a gear type positive displacement pump driven through the timing gears, which ensures the pump
operates when the engine is running.
It is the oil pump function to supply oil to the other components of the engine. The pump consists of: a pump
body, cover or suction hood, two gears (a driving gear and an idler gear), and an overpressure safety valve.
Overpressure safety valve
1/6
Page 92
PRODUCT INFORMATION
2.3.2
IC-C-D-25-005e C
INDEX
February 2012
DATE
Dep. 2
DESCRIPTION OF LUBRICATION SYSTEM
FOR “V” ENGINES
2.3. OVERPRESSURE SAFETY VALVE
The overpressure safety valve or relief valve lies at the outlet of the oil pump. Its function is to control pressure
and discharge oil directly to the sump if the impulse pressure exceeds the rated pressure (8 bar / 116 psi), thus
protecting engine components from failure. The valve is fixed to a bracket attached to the ribs of the oil sump.
(See Fig. 1).
2.4. LUBRICATING OIL PRESSURE REGULATING VALVE
Its function is to regulate the lubricating oil pressure of the engine. It is located at the inlet to the oil filters and is
rated at 4.5 bar (65 psi). Its function is to discharge the surplus oil when the rated pressure is exceeded, ensuring
that the oil pressure is constant under all the engine operating or load conditions.
2.5. THERMOSTATTED OIL VALVE
Its function is to control the minimum oil temperature. It is located at the inlet to the oil cooler. It operates in such a
way that when the oil temperature drops below a preset value (75ºC), it prevents oil from going through the
cooler, allowing oil to heat up quickly. Once the minimum oil temperature has been reached, all the oil will flow
through the cooler.
2.6. OIL COOLER
These engines have an external oil cooler, which in its standard version, is the pipes type, housed in a casing.
The design of the oil cooler can be adapted to the application requirements.
2.7. CLOGGED FILTER VALVE
Situated upstream of the filters, this valve would divert oil to the sump in order to avoid damage to filter cartidges,
should pressure exceed the set limit of 6 bar due to the clogging of the filters.
2.8. SAFETY OIL PRESSURE SWITCH
All V-engines have a low oil pressure switch in the main lubrication gallery. If the lubrication pressure is
insufficient, the alarm will go off as a warning about the need for service or activate the engine shutdown.
When oil flows back into the sump due to the clogging of the filters, it is normal that pressure drops after the filters
and this pressure switch activates the alarm.
It is possible to have a high oil pressure switch. This will be placed at the inlet to the oil filters. It will operate,
activating an alarm, when the oil pressure rises due to the clogging of the filters or if the oil flow is blocked.
2.9. OIL FILTERS
The filters are of the interchangeable and full flow cartridge type, oil being entirely cleaned in a set of three
parallel filters. They have no bypass or non-return valve. Filtering efficiency is 99% at 30m and >50% at 15m.
2.10. JET PRESSURE REGULATION VALVE
On a V-engine, this valve lies at the end of the main lubrication gallery (side opposite the oil inlet to the engine
block). It is rated at 3 bar (43.5 psi) and its function is to allow oil to pass to the jet gallery and to the piston
coolant jets themselves when the rated pressure is reached.
O&M_2.002211.810_A_10_2016
2/6
Page 93
PRODUCT INFORMATION
2.3.3
IC-C-D-25-005e C
INDEX
February 2012
DATE
Dep. 2
DESCRIPTION OF LUBRICATION SYSTEM
FOR “V” ENGINES
2.11. CENTRIFUGAL FILTER
Combustion in diesel engines produces a large amount of soot or very fine-grained pulverised carbon particles
that are absolutely not retained in the oil filter.
In the case of gas engines, the problem is the presence of oil-borne contaminants in fuel gas (mainly biogas)
rather than the production of soot.
Centrifugal filters are not so common as the oil filters; their underlying principle is the heavier weight of solids
compared to oil. A centrifugal filter comprises a rotating circular body on the wall of which the solid particles settle,
while purified oil flows through a central duct to the oil sump.
2.12. BLOW-BY GAS EXHAUST SYSTEM
KOHLER engines can come with a passive or an active blow-by gas exhaust system.
2.12.1. Open or passive system (for diesel, gas and ethanol engines)
The commonest standard blow-by gas exhaust system is the open system with an oil separator followed by an
exhaust pipe to the outside. These are the components of such an open gas exhaust system:
- The crankcase, which finally collects the gases that escape from the combustion chamber through the
interstice between the piston rings and the cylinder liner.
- The blow-by gas breather. It is made of one wire-mesh separator which separates the gas-borne thick liquid
drops and feeds them back to the crankcase by gravity.
- An exhaust pipe.
2.12.2. Active o blow-by gas recirculating system (only for gas engines)
The blow-by gas recirculating system aims at introducing the crankcase gases, in a clean and effective manner,
into the intake air stream.
In the blow-by gas recirculating system, there is a filter that cleans the gases before they flow into the engine.
O&M_2.002211.810_A_10_2016
3/6
Page 94
PRODUCT INFORMATION
2.3.4
IC-C-D-25-005e C
INDEX
February 2012
DATE
Dep. 2
DESCRIPTION OF LUBRICATION SYSTEM
FOR “V” ENGINES
R
3
4
8
7
1 Oil pump
2 Safety valve
3 Regulation valve
4 Thermostat valve
5 Oil cooler
6 Clogged filter valve
7 Oil filters
8 Jet pressure valve
9 Oil sump
5
9
2
1
O&M_2.002211.810_A_10_2016
3. OPERATION
- Oil is drawn from the sump through the grille in the suction tube by means of the oil pump.
- The pump supplies a specific flow of oil at a certain pressure. If the pressure exceeds 8 bar (116 psi), oil is
drained in the safety valve directly to the crankcase.
- Oil flows from the pump to the thermostat valve unit, reaching first the lubricating oil pressure regulating valve.
This adjusts the oil flow to maintain a pressure of 4.5 to 5 bar in the gallery under normal working conditions.
- If the oil is cold (less than 75ºC), it flows through the thermostat valve, avoiding the cooler. Under normal
operating conditions (hot oil), it flows through the cooler.
- Afterwards oil arrives at the filter access gallery where the clogged filter valve is to be found. If, for this reason
(filter clogging), the pressure exceeds 6 bar, oil will be diverted to the oil sump.
- Once filtered, a small amount of oil flows to a distributor that lubricates the auxiliary water pump as well as:
the right injection pump , on diesel engines;
the turbocharger on HGM gas engines.
- The other portion of oil flows to the main lubrication gallery and is distributed in parallel towards:
The right camshaft, cylinder heads, rocker arms and injection pump drive.
Oil flows inside the camshaft, from end to end, along the longitudinal direction of the engine block. Also,
oil is distributed through individual passages to the bearings and the auxiliary rocker arm shaft. Holes in
the rocker arm shaft bushing allow oil to lubricate the camshaft rollers.
Part of the oil that flows through the camshaft flows into an external channel which is machined on the
engine block and cylinder head and conveys oil to the main rocker arm shaft. From this point, oil passes
4/6
Page 95
PRODUCT INFORMATION
2.3.5
IC-C-D-25-005e C
INDEX
February 2012
DATE
Dep. 2
DESCRIPTION OF LUBRICATION SYSTEM
FOR “V” ENGINES
through the shaft orifices to the oiling holes of the intake and exhaust valve rockers and to the valve
stems. The rest of the cylinder head is spray-lubricated.
Finally, on diesel engines, oil will lubricate the injection pump drive.
Then, oil lubricates the timing gears.
Next, oil reaches a distributor that guides the oil stream to the turbocharger (except for the HGM engine) and
to the regulator.
Now, ahead of the oil distributing point to the crankshaft, oil reaches another distributor that directs oil partly to
lubricate the left injection pump (on diesel engines) and the water pump drive and partly to proceed to the
centrifugal filter, if any.
Afterwards, oil passes through a hole to the crankshaft, bearing caps, big and small ends of the connecting
rods.
On reaching the crankshaft, oil flows through internal channels which lead it to the bearing caps and big-
end bearings. Oil circulates through ducts inside the connecting rod to reach the upper part of the conrod,
i.e. the small end bushings and the pin, which are coated with a lubricating film.
The cylinder walls and the piston pins are lubricated by the amount of oil that leaks out from the ends of
the bearings and is splashed by the rotating action of the crankshaft. Excess oil is removed from the
cylinder by the scraper ring and fed back into the crankcase.
Thereafter, oil reaches the lubricating point of the camshaft on the left-hand side of the engine. It lubricates the
camshaft, rocker arms and cylinder heads on the left bank as well as the drive of the left injection pump.
At the end of the main lubrication gallery, side opposite inlet, oil arrives at the jet pressure valve that directs oil
to the left and to the right of the engine, through the jet gallery that leads it to the piston coolant jets.
Finally, oil returns to the oil sump
O&M_2.002211.810_A_10_2016
5/6
Page 96
PRODUCT INFORMATION
2.3.6
IC-C-D-25-005e C
INDEX
February 2012
DATE
Dep. 2
DESCRIPTION OF LUBRICATION SYSTEM
FOR “V” ENGINES
O&M_2.002211.810_A_10_2016
GEAR
PUMP
Grille in
suction tube
SAFETY
VALV E
P > 8 bar
YES
NO
Sampling
PRES.
REG. VALVE
P > 4,5 bar
YES
High pressure
Distributor
NO
THERMOSTAT
switch
YES
FILTER VALVE
Low pressure
switch
Injection pump (1)
OIL
COOLER
YES
VALV E
> 75º C
Tª
NO
CLOGGED
> 6 bar
P
NO
FILTERS
Turbucharger (3)
MAIN LUB. GALLERY
Camshaft
Timing gears
Crankshaft Conrods
Distributor
Distributor
Camshaft
JET PRES.
VALV E
P
> 3 bar
Aux.
rocker
shaft
Aux.
rocker
shaft
Main
rocker
shaft
Injection pump drive (1)
Regulat
Turbocharge (1) (2)
Centrifugal filter
Injection pump drive (1)
Water pump drive
Main
rocker
shaft
Injection pump drive (1)
Jets
Piston
head
Rockers
Rockers
(1) F/SF diesel engines
(2) FGLD/SFGLD gas and SFE ethanol engines
(3) HGM engine
OIL SUMP
6/6
Page 97
PRODUCT INFORMATION
INDEX DATE
Dep. 2
IT-C-A-25-002e
F
March 2015
AUTOMATIC ENGINE OIL LEVEL CONTROLLER
1/4
2.3.7
1. INTRODUCTION
If engine-driven equipment is intended for 24-hour operation or similar, it is recommended that the engine should
be fitted with an oil level controller.
O&M_2.002211.810_A_10_2016
Fig. 1 – General layout on 180/240 series engines
Fig. 2 – General layout on 180/240 series generating sets
Page 98
PRODUCT INFORMATION
INDEX DATE
Dep. 2
IT-C-A-25-002e
F
March 2015
AUTOMATIC ENGINE OIL LEVEL CONTROLLER
2/4
1
Automatic oil level controller
2
Oil tank
3
Filling hose
4
Oil sump to level controller hose
5
Venting hose
6
Lube oil level indicator (Refer to IT-C-A-25-009e or IT-G-A-25-009e)
6
MT-90
Digital Tachometer
bar
3
1
2
0
4
5
6
7
60
40
80
100
120
°C
110
3
4
1
5
2
2.3.8
O&M_2.002211.810_A_10_2016
Fig. 3 – General layout on 360/480/560 series engines/generating sets
Fig. 4 – Automatic Oil Level Controller
Page 99
PRODUCT INFORMATION
INDEX DATE
Dep. 2
IT-C-A-25-002e
F
March 2015
AUTOMATIC ENGINE OIL LEVEL CONTROLLER
3/4
1
Oil supply hose
2
Venting hose
3
Oil controller hose to oil sump
4
Height adjustment screw
ENGINE
HEIGHT (MM)
F/SF 180/240
122
SFE/FG/FGLD/SFGLD/SFGM/SFGRD 180/240
92
HGM240
122
F/SF 360/480
92
SFE/FGLD/SFGLD/SFGM/SFGRD 360
55
SFE/FGLD/SFGLD/SFGM/SFGRD 480
92
SFGLD/SFGM/SFGRD 560
47
HGM420/560
92
2.3.9
O&M_2.002211.810_A_10_2016
2. DESCRIPTION AND ASSEMBLY
The oil level controller is a mechanical actuator placed on the oil sump at the bottom of the engine. It is equipped
with a floater inside a small reservoir which opens or closes the oil flow into the engine crankcase.
When assembling the level controller in the sump, the latter is equipped with a universal bracket with two screws
whose task is not only to secure the unit to the engine but to adjust the height thereof such that with the engine
running and oil hot, the indicator level should be aligned with the oil level in the engine crankcase.
Therefore, the height from the adjusting nut to the oil sump base will vary according to the engine model.
Variations with respect to its height or position on the engine can cause the oil sump to overfill. It is also important
to tighten the fasteners correctly to prevent engine vibrations from altering the position of the oil controller (see
enclosed table).
As the automatic filling equipment is connected by a hose to the oil sump, the oil level displayed always matches
the actual reading, whether in applications where ventilation airs to the atmosphere or for applications with
crankcase gas recirculation to intake. This crankcase ventilation hose (2) must be 12mm in diameter and the
connection must be located above the oil level. Improper installation of crankcase ventilation can cause overflow.
The discharge hose to the crankcase (3) should be approximately 25mm in diameter and should be free from
buckling.
The charging hose (1) should have a downward pitch with no sags and be 12mm in diameter.
If fed from a booster tank, the height thereof must NOT exceed 4.6 m. If this height is exceeded, the oil sump may
overfill due to excess inlet pressure.
Page 100
PRODUCT INFORMATION
INDEX DATE
Dep. 2
IT-C-A-25-002e
F
March 2015
AUTOMATIC ENGINE OIL LEVEL CONTROLLER
4/4
2.3.10
O&M_2.002211.810_A_10_2016
When the engine is running, the oil level in the display must be within the normal operating range.
When the engine is stopped due to oil backflow in the circuit, the oil level will exceed this range and overflow will
occur, but once the engine has been started, it will return to its regular position.
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